Distribution Management in a Warehouse for Hardgoods

Manufacturing Management

Durable Goods

In today's dynamic manufacturing landscape, relentless pressure from competition, unexpected disruptions, and ever-evolving consumer demands makes cost control paramount for long-term success. VAI's Manufacturing Suite empowers manufacturers to streamline operations, optimize production processes, and gain real-time visibility into costs.

Key Features:

Work Order Management

  • Manufacturing Work Orders simplifies work order creation for various production scenarios, including make-to-stock, make-to-order, and planned orders
  • Bill of Materials (BOM) management for handling of complex product structures with ease. Support for multiple BOMs for a single finished item, accommodating engineering revisions and custom configurations.
  • Create routing steps for a clear direction to making finished goods
  • Complete integration with inventory management to ensure you have the necessary materials to fulfill work orders. Identify potential shortages and substitute readily available components if needed.
  • Production cost tracking for valuable insights into manufacturing costs with real-time production cost calculation and general ledger posting
  • Calculate material, labor, and overhead variances for a clear picture of production efficiency
  • Comprehensive suite of reports for in-depth analysis of production performance, including standard vs. actual cost comparisons, material variances, scrap reporting, and labor efficiencies

Material Requirements Planning (MRP)

  • Embedded MRP to streamline material purchasing and scheduling
  • Analysis of sales orders, production orders, purchase orders, current inventory levels, and sales forecasts to generate precise material requirements
  • Insights into future material needs on a daily, weekly, or monthly basis
  • Complete supply chain visibility with drill down to critical purchase order due dates, manufacturing order due dates, and specific customer orders associated with inventory commitments
  • Generate suggestions for manufacturing work orders and purchase orders, which can then be adjusted and automatically converted into actionable plans

Shop Floor Control

  • Record material and labor usage on the shop floor using tablets, mobile devices, or handheld scanners
  • Real-time monitoring to track production progress, material usage, and available machine capacity in real-time, facilitating informed decision-making

Product Quality

  • Manage testing procedures and maintain quality control throughout the manufacturing process
  • Establish an unlimited number of custom tests or grouped tests to maintain maximum product quality
  • Assign tests to specific items or specific routing steps and track results for received goods and finished products
  • Route production back to a previous operation or flag scrap items based on quality control failures

Capacity Requirements Planning (CRP)

  • Powerful inquiries allow users to view soft, firm and planned demand, allowing a detailed analysis of both actual and projected capacity requirements.
  • Summary information helps you spot situations where capacity is short or long, enabling you to shift production and manage resources efficiently.
  • Multiple views allow you to analyze machine, work center, and department capacities. Extensive capabilities exist to drill down into detailed scheduling data including orders making up the demand, as well as analysis of bottlenecks.
  • Alternate routings allow automatic calculation of "available to promise" (ATP) dates for easy bottleneck resolution.