abas ERP | Production Summary


Rising costs, raw material shortages, increasingly more complex manufacturing processes and customers’ higher quality requirements make flexibility a key requirement in production and production planning. Regardless of how your production is structured – discrete or process-oriented, custom, series or mass manufacturing – abas ERP provides the tools your team needs in order to plan resources and deadlines and monitor production processes. End-to-end transparency means that you can adapt quickly to changing customer requirements.
abas ERP helps you manage your entire production processes, from planning, work preparation and release through to confirmation of the times and quantities required. Clearly displayed dates, materials and capacities ensure you see the detail you need, giving you the freedom to intervene where necessary. Efficient processes along the value-added chain support employees and ensure lean production.

abas ERP supports the following production processes:
  • Make-to-order production
  • Small series production
  • Series production
  • Mass production
The system accesses the data pool created in the master data.

Production overview
Production overview provides you with a role-based overview of all allocated activities – including due dates as well as the material and capacity situation. You can analyze your activities over a specific period and click to toggle to different applications to perform additional actions, such as processing active work orders and work order suggestions, completion confirmations, amendments to production lists or machine loading and scheduling.

Automatic work order suggestions
For many manufacturing companies, it is imperative that their ERP system automatically generates work order suggestions from new or existing BOMs, which includes checking on whether the required products, raw materials, employee and machine capacities are available. In abas, materials planning and date scheduling automatically generate work order suggestions. Machine loading and scheduling can be manually displayed, edited or released for production. You can adjust the calculated start and due dates as well as reduce or increase quantities. Splitting the quantities suggested by the system over individual sales orders with different due dates is also an option. 
  • Automate production processes: abas ERP identifies requirements and automatically generates work order suggestions, which include the quantity to be produced and the required completion date
  • Simplification of work: With abas, your production department has access to an overview of all open work order suggestions. Here, you can easily convert individual or multiple suggestions into work orders
  • Faster processing guaranteed: The direct conversion of work order suggestions into work orders saves time and avoids errors caused through duplicate data entry
  • Keep stocks at a certain level: This feature allows you to define minimum stock levels for all products in order to generate automatic work order suggestions when the inventory in stock falls below a certain level
From work order suggestion to work order
Releasing a work order suggestion creates work orders, work slips, job tickets and pull lists. Then, an availability check of the required materials is run automatically. Required materials that are not in stock are displayed in the missing parts list. At any time, released work orders can be moved to different dates or their content can be changed, and the system displays the work order’s processing status. The procurement status info system provides you with information about parts currently being procured. 

Plan external processing: extended workbench/external production
In the standard order production list you can plan work steps that need to be processed externally. Scheduling then provides information about the currently required level of external services. 

•External production processes:
  • Requesting/ordering of external processing or production
  • Distribution of semi-finished products/provided parts to the subcontractor via packing slip
  • Stock monitoring in subcontractor's consignment warehouse
  • Receipt postings of processed parts through a goods receipt slip with completion confirmation to production
  • Entry of subcontracting costs from receipt invoice and inclusion in the final costing
Distinction between series parts and prototypes
A prototype is often produced before a product goes into series production. The costs incurred for the production of prototypes are often much higher than for the subsequent series models, as the efficient production capabilities of series production are not yet available. With project-related manufacturing in abas ERP, you can distinguish between normal series production and the production of prototypes and pilot series. 

Variant management
Variant and custom manufacturers need special production structures for specific orders or product variants. You can map these easily in the abas ERP software by maintaining standard, alternative or supplementary product structures. 

This enables you to efficiently plan a large number of different combinations and manage them in the product master, giving you an overview of the composition of a product at all times.
  • Adjustments during ongoing processes: You can modify parts of the order-related Bill of Materials (BOM) or operations in the sales order-related task list, even if the production process has already begun. In this way you can, for example, adapt BOMs for quotations or orders and reliably calculate delivery times and costs
  • Flexible planning: Each product can have alternative BOMs. This means that you can easily reschedule in the event of material shortages or machine bottlenecks, production lists can be gradually refined and variants can quickly be created
  • Prevent / control bottlenecks: Alternative BOMs help you confidently manage bottlenecks. You can quickly change the operations for a product, optimize the production batch size by using alternative equipment, or release capacities for other processes
  • Time-based variants: Assign a validity period or expiration date to BOMs in order to seamlessly coordinate variants chronologically
  • Faster processes: Start your production with components and parts already available while other parts are still being finished, parts with long delivery times are being procured or the design process is still in progress
Order/project-related production list
You can map special production structures to a specific order by changing the BOM and task list for the specific order. Single parts, assemblies, materials or operations in the production list can be deleted, replaced, modified or added while the production process is in progress.

Growing project-related production list
An important requirement for make-to-order manufacturing is to be able to schedule project materials in the right quantity and for the right dates, even though the BOM is not complete at the time production begins. abas ERP supports this process. You maintain the BOMs and task lists, also known as production lists, in parallel with design. Based on the growing production list, you can procure parts and produce the modules before the machine or plant has been fully constructed. The production list grows with each component released by the production department until the production list is complete at the end. Single parts, assemblies and materials can always be uniquely assigned to projects.

Editable order production list
The editable order production list allows order-related changes to any level of a production list. In the case of material and machine bottlenecks, rescheduling is simple; more details can be added to production lists gradually, and variants are quickly created. The overview of a product structure is always available. Info systems within abas ERP help your engineers and production planners review and maintain complex multi-level BOM structures. 

Combined production
Combined production describes the simultaneous manufacturing of multiple different products in a single production process. The products are posted as a stock receipt and can then be used internally and sold. Combined products are entered in the production list with a negative quantity. You can use this both in the neutral production lists of the product master and the currently scheduled order production lists. The combined products will be taken into account when the BOM entries are created -- manually or automatically by production -- and will be posted as stock receipts.

The costs of the combined products are simultaneously taken into account in the final costing of the work order, reducing the material costs of the manufactured main product. The costs of the combined products are also deducted from the material costs of the main product in the preliminary costing. Scheduling treats combined products in the production lists as planned receipts.
Available capacities are loaded with the planned/target figures for the work order suggestions and work orders.

Work order completion confirmations
If work orders are processed completely or partially in production, the finished products can be  automatically posted to inventory through completion confirmations, freeing up machine capacity. The raw materials required for production, and their associated costs, are issued to Work in Process (WIP) and will be applied to the finished goods. You can create a completion confirmation using a workstation, or a connected scanner, mobile device or radio frequency identification (RFID).

You can also generate completion confirmations automatically. For example, materials that have operations allocated to them in the structure, or materials that are connected with the operation "Prepare material," are automatically debited. The automated completion confirmations can also be linked to any other point in time or event. A defined completion confirmation result can, for example, create a mandatory entry in the warehouse.

Production reports
Comprehensive production reports are essential to give you an overview of the performance and profitability of your company. Enable your team to return relevant data about completed or suspended processes. 

You can use this data to assess the efficiency of your company and develop effective growth strategies.
  • Actual quantities: Your employees in production can easily change the quantities in the standard production list to record the materials actually used and update the available stocks
  • Exact costs: Reported scrap and processing times can be evaluated and used for capacity planning, which allows the accounting department to calculate the exact costs
  • Comprehensive overview: With reports and evaluations, you and your production staff can track current activities and forward valuable status information from production to your sales and customer service teams
  • Report operating faults: Faults such as technical defects in machines or material bottlenecks can be reported. This allows inefficient processes to be identified and appropriate countermeasures to be taken
  • Valuable insights: Maintain an overview of and report on production-related key performance indicators, such as material consumption, operating costs, downtime, scrap quantities, etc