Factory Control Systems

Bedding / Upholstery Management System

Standard System includes the following modules: Bills of materials, costing, stock / inventory control, sales orders processing, purchase order processing, works order processing, MRP II, Using Microsoft SQL Database.

Bedding & upholstery management system: Use parametric formula e.g. in bills of materials to auto adjust the size of all components.

For bedding companies choose options for tick, label, thread, label foam, backing, handles, vents, spring, frame, zip, and link etc. with information cascading to all relevant areas of manufacture and purchase.

Features of Bills of materials

• Full database library for all components, items and services that the system needs to recognize, by item code and description, along with all the various operational 'flags'
• Fully integrated multiple levels of the Bills of Materials, with full flexibility to go as 'deep' as you want to Labour and material percentage shrinkage / wastage features
• Automatic calculation of any fluid applications such as lacquer / paint and associated cost, based on area plus values entered for density, coverage and number of coats
• Facility to hold multiple operations, and the material and labour associated with each operation, at each level of the Bill Copy bill feature for fast creation of similar bills.
• 'Fish' diagram of complete Bill of Material, with all components, sizes and formulae used at every level, that are automatically created for easy viewing to help to ensure the Bills are accurate and complete
• Facility to enter product 'Options' e.g. Colour, size etc. against common or standard components, which can be stored in the products BOM set-up, and subsequently shown in the SOP module for order entry, customer quotations, and Costings for the product, and which can be entered without having to make a fresh BOM for each new product, on each occasion
• Once a part number and description have been created, there is no more 'keying-in', just 'point and click'
• Facility for entering automatic formulae for 'parametric' conversions, which will calculate and show the number and sizes of the parts required to make up a 'saleable' item, according to the size entered for the item on the order, and that then uses a common or standard BOM
• Easy entry for additional new 'Options' for any items that have been set up as possessing a selection of colours / sizes etc. in order to allow a BOM to be quickly and accurately be put together.

Features of Costing

• Effortless calculation of selling prices
• Can build up costs to any level of the Bill of Materials, and report on 'rolled-up' costs at each level
• Facility for auto-calculation of costs working up the Bills using current or standard costs
• Click on an item to pick up material and labour costs from the Bill of Materials, or enter an estimate and the system will automatically work out the portion of overhead to apply
• Reporting of costs at current or standard as required, with facility to transfer current to standard at any time, for budgeting and variance reporting purposes
• Global default Percentage figures for consumables, overheads, distribution costs and profit or specific item percentage values, can be set. The system will hold these percentages and re-calculate the values as costs fluctuate
• Versatile options on costs generated by the BOM allows the user to build in specific operational overheads, to recover costs of capital equipment e.g. CNC machines
• Enter a specific selling price, and the system will show the profit made at that price
• Option to work from a fixed selling price with set increments for specific options (automatically calculated as options selected) -Or cost plus margin (global or specific) to determine the selling price. These costing rules can be set at item level as appropriate
• Enter the profit, and the system calculates the selling price, ensuring overheads, as entered, are correctly covered
• Facility to enter default percentages for consumables, distribution, and overheads, which are applied if there are no other fixed values specifically entered against an item
• Simple entry and application of Standard Costs v Current Costs for easy viewing of variances

Features of Stock inventory control

• Control movement between as many stockrooms or locations as your business requires
• Option to set purchased product by daily / weekly / monthly policy, for efficient purchasing and cash allocation
• Information on physical, allocated, quarantined and available stock routinely viewed on screen, or printed to hard copy
• Facility to provide information on usage on every item, along with ABC analysis
• Facility to record stock in multiple rack / bin locations for each stockroom
• Option to automatically control stock re-order points by using minimum and maximum stock level parameters
• Stock valuation report summarised at standard or current costs by stockroom, with an accompanying total for all stockrooms
• Stock reports by item code / description given by stockroom highlighting stock levels as low, high, or OK, according to minimum levels and resource requirements, along with the various 'flags' and usages set against the item
• Facility for taking on stock through Stock transfers, Stocktake adjustments, and Quarantine by just keying-in the quantity and clicking on the reason for entry, or by using the latest barcode technology for labeling and remote data capture units
• Stocktake sheets printed out by stockroom name, to help in identifying what and where the stock should be, and to provide an 'easy prompt' for an entry
• Facility for entering an EOQ (economic order quantity), to ensure internal and external orders are ordered in acceptable batch sizes
• Easy viewing in tabular form, of all product 'Options' that have been set up and validated as being acceptable to sell to customers, and that have also been evaluated through a Stock Master 'cost roll-up'
• Facility to 'auto-create' the Stock Room Master record without the need to individually set one up for each item
• Option to set 'buy to order' for back to back purchasing policies keeping any buffer emergency stock.

Features of Sales Orders Processing

• Multiple address facility for acknowledgement, invoice and delivery held for each customer
• Default addresses automatically selected and entered when an order / quotation is created
• Alternative addresses can be selected from the available addresses, specific to the customer, or if the address is a one off delivery address, it can be entered directly against the order as it is being entered
• Optional cross reference to customers' product descriptions, codes and prices can be held for each customer
• Ability to hold each customers' stock numbers and references (catalogue / brochure number), if different from the manufacturing part number / description
• Facility to hold multiple prices per item, with options for price breaks for different quantities, along with discounted prices for a date range, by product, by customer
• Facility to enter any combination of 'Options' of colour or size etc. against an item, that have been set up and validated in the Stock records, and which also show as a list of all possible 'Options' for that item on the order details screen for easy selection or amendement when entering the order
• Automatic 'prompts' and checks to prevent invalid orders being entered or released for manufacture
• Easy switch from 'quotation', to 'order' status, enabling the release of an order for manufacture to the next MRP 'explosion', and again an easy switch to 'completed' status once the order has been despatched
• Automatic Order Acknowledgement / Quotation report available in detail, or by summary, depending on the status of the order
• Facility to enter an instructional order for product returns, and setting the order to a 'returns' status, along with entering the appropriate reference data for easy tracking
• Ability to enter multiple reference numbers and data against each order - i.e. project / sales order / customer ref / sales ref / our ref / etc.

Features of Purchase Orders Processing

• Form layouts can be customized to suit the format of business stationary, along with automatic system allocation of unique order number references against each Works and Purchase Order
• Automatic 'prompt' reports to show the Purchasing suggestions each time a fresh MRP run has been done, that only require a confirmation to actually place the Purchase Order
• All requirements print to screen before confirming the hard copy print, by selection of Work Centre or Supplier name
• Seperate 'picking list' for purchased stock items, that can also be booked either through keyboard or by barcode
• The system will handle part-order receipts, and will leave the order 'open' until complete order is booked as received, and can be set to allow the booking of receipts either through keyboard or by barcode
• Facility for the system to automatically store currency conversions, preferred supplier information, and latest cost against each item

Features of Works Orders Processing

• The system has the facility to monitor production through both multiple, and limited numbers, of routes, operations and processes as required
• Facility to print Works Orders for each Work Centre name, or by individual Project No., according to how your business operates
• Screen automatically displays all open orders against each item, plus the quantity outstanding at each operation, for each order
• Optional 'Back-flush' feature automatically removes components from issuing Stock Room, when Works Order is booked as completed
• Daily recording sheet for each Work Centre / Operation which shows all requirements and what overdues are outstanding
• Facility to automatically 'multi-book' by Work Centre name, or to individually book a Works Order through keyboard or by barcode, with indefinite number of partial bookings allowed
• Full and comprehensive 'suite' of reports available to show all transactions for both Works and Purchase Orders, that allows the user to see how many are outstanding, and on what date the last issue or receipt took place, along with all 'usage' information, MRP requirements and stock levels

Features of MRP II

• Software has been developed for fast execution, rather than taking the 'traditional' hours for overnight runs
• Facility to run full MRP explosion for the full order book or an individual Project No., through every level of the Bill of Materials, checking stocks and outstanding Works Orders and Purchase Orders at each level in minutes
• Feature for automatic reallocation of stock in each stock area against current live orders
• Options to run MRP from either Customer Orders or from Works Orders, with a 'suite' of reports to show suggested Purchase and Works Order requirements by unique project No. / by date / by item, along with their stock records, and a 'button' for the subsequent auto-creation of the actual orders on the system, ready for confirming for print out and processing

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