Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
BOM Management |
Handling multiple bill of material, revision, change and compliance management |
With mbas user can choose multiple BOM for an item at the time of planning and productions |
Efficient Capacity Planning |
Failure in efficiently planning machines and production of multiple items |
mbas offers planning & production as per RCCP, CRP requirements |
Vendor Management |
Cost optimization, complex vendor eco systems. |
Defined functionality for vendor management for purchase and production. |
Design Change |
Continuous design change |
Mbas follows engineering change order (ECO) process that outlines the proposed change, lists of products, parts that would be affected and approvals of the individuals who would be impacted with implementing the change. |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Optimizing production lead time |
Not being aware of the production lead time of each product |
mbas offers efficient tools to run planning and scheduling for each product, with automated production lead time it help users to thoroughly analyze every step of the production process, refine inefficient steps and remove unnecessary steps in the process |
Die Management |
Challenges in manually monitoring the life of a die |
mbas automates the process of monitoring the life of a die, this equips the users to better manage dies and significantly improves the quality of the produced items. |
Process parameter tracking |
laborious paper based parameter (temperature, pressure, etc) tracking which is prone to errors |
Wherever and whenever required mbas prompts for process parameters and saves all the data. In case a quality issue arises it verifies standard to actual parameters and alerts users on the deviation. |
Optimum Capacity utilization |
Time consuming capacity and load calculation |
With mbas users have the flexibility to plan the production and provide capacity conditions for optimum utilization. |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Every chemical combination with different specifications becomes a product or and SKU Lack of recipe management |
mbas offers recipe management taking potency factor into account. with mbas users have the flexibility to issue items with different concentration factors if the required concentration is not available. |
mbas offers recipe management taking potency factor into account. with mbas users have the flexibility to issue items with different concentration factors if the required concentration is not available. |
Different packages of the same product |
Lack of awareness on product specifications |
With mbas users can maintain separate recipes for production and Packaging |
Efficient Inventory Management for shorter shelf life |
Improper administration of warehouses Poor inventory valuation method |
mbas offers: Accurate inventory visibility Multi-level warehouse structure Inventory Issues based on FIFO strategy |
Lot traceability and recall management system |
Lack of lot recall system Lack of metrics & tools that aid in decision making |
mbas offers flexible reports, one of which is a LOT recall report which identifies lots of raw materials for a specific finish good |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Optimizing production lead time |
Not being aware of the production lead time of each product |
mbas offers efficient tools to run planning and scheduling for each product, with automated production lead time it help users to thoroughly analyze every step of the production process, refine inefficient steps and remove unnecessary steps in the process |
Reduction in production cost |
Higher production costs because of Rework on the components/outputs being produced |
mbas tracks each and every components involved and operations performed. it captures and draws a comparison on the actual cost of production to the of the estimated cost. |
Inventory reconciliation |
Laborious, often error prone stock reconciliation process |
Mbas offers easy inventory management with clear visibility of stocks. To avoid reporting loss of stock at the end of the financial year mbas offers flexibility in setting up the counting frequency. |
Handling quality and traceability data |
Manual interaction exist |
mbas offers Effective lot tracking & serial number tracking to differentiate the produced lots. |
Pain Areas |
|
Mbas Best Practice |
---|---|---|
Improve customer satisfaction | Offer best price and quotes, maintain long term contracts and agreements, Offer incentives against their performance, Improve customer service & responsiveness, Available-to-Promise and order confirmations, Drop shipments –delivery from vendor to customer directly |
|
Manage purchase lead times for materials like furniture, cement, wood, furniture | Proper selection of vendors through periodic evaluation on performance, Centralized\decentralized\semi-centralized purchasing, Long term contracts and agreements after negotiations. Demand consolidation and optimization with flexible drop shipments. |
|
Manage incentives and rebates | Flexible quota definition, Flexible incentive and rebates disbursements |
|
profitability goals | Increase profits from trading business by determining competitive prices for your products while integrating the logistics and financial aspects. |
|
Available to promise | Proper order confirmation, Order Scheduling in Sales Order, Available-to-promise. |
|
Exchange information with Manufacturers / Suppliers and customers | Collaboration between manufactures, supplier and customer, Web-based Solution –Access Internet anywhere, anytime. Vendor log-in to view publish quotes, view orders and speed up shipments. Customer log-in to float RFQs and view quotation, place orders and view stock and order status |
|
Inventory management | Accurate inventory visibility, Efficient Warehouse Management supporting multi-level W/H structure, Configurable item properties, Inventory Replenishment Planning –Order Methods, Order Qty etc. Seamless integration across different functions and business processes. |
|
Effective Decision Making related to Critical issues | Real-time update of accounts and other key processes on invoicing, returns etc., Analytics with built-in KPIs to monitor real-time performance on multiple dimensions, Consolidation –multi-company, multi location scenarios |
|
Control credit limit | Flexible credit limit controls on customer, customer type, customer group and region wise. |
Pain Areas |
|
Mbas Best Practice |
---|---|---|
Inventory traceability | mbas uniquely builds, maintains and identifies serial numbers/LOT/batch number for products. |
|
Inventory Visibility | Accurate inventory visibility, Efficient Warehouse Management supporting multi-level W/H structure, Configurable item properties, Inventory Replenishment Planning –Order Methods, Order Qty etc. Seamless integration across different functions and business processes. |
|
Maintenance of consignment stock at retailer’s location | Streamlined Consignment-OUT Management |
|
Promotions & Rebates | Flexible Schemes and Pricing definitions |
|
Single Order consisting of items with multiple specifications | mbas offers flexbility in creating and storing multiple specifications (dimensional ex: length, breadth etc) changes for the same item. |
|
High Procurement costs | Mbas reduces procurement cost and lead time through streamlined purchasing and ensures on-time delivery from the vendors place through detailed schedules. |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Improve operational efficiency And productivity |
Challenges to maintain both product mix and product volume |
Mbas optimizes planning by automatically calculating lead time based on routing details |
Respond quickly to changing consumer and customer demands |
No integrated plan to achieve business goals |
Forecasts and plans for anticipated demand for products. SOP to integrate the entire department’s plan to achieve organizational goals. |
Availability of right raw materials at right quantity and at a right time |
Lack of ordering system in place |
Mbas MRP alerts users regarding materials and the optimal quantity to be ordered |
Order wise Costing |
Lack of proper costing methodologies |
mbas offers order based costing |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Manage Products With Shorter Life Cycle |
Lack of awareness on product life cycles. Poor focus on Value-Added Services. |
Product management from creation to exclusion SKU & Variants Management Specific planning on seasonal items Promotions planning & execution Planning of prices, discounts and offers Product performance and profitability analysis Support custom packaging, product labeling etc as per customer requirements Flexibility to add services with products |
Efficient Inventory Management |
Improper administration of warehouses. Poor inventory planning. Poor coordination amongst sales, purchase, & inventory processes. |
Accurate inventory visibility Multi-level warehouse structure Configurable item properties (location, lot, serial no., expiry, bill of entry, etc) Inventory Replenishment Planning –Order Methods, Order Qty etc Seamless integration amongst different functions and business processes |
Managing Purchase Lead Times |
Lack of collaboration with vendors. Improper planning. Lack of control on vendor. |
Proper selection of vendors through periodic evaluations on performance Centralized\de-centralized\semi-centralized purchasing Long term contracts and agreements after negotiations Demand consolidation and optimization Drop shipments |
Differentiating business value adds |
Lack of proper Point-of-Sale system. Poor customer service. |
Touch screen menus with graphical user interface, Microsoft OPOS compliant Apply price, promotions, discounts and taxes to items Flexible tender options -cash, credit card, debit card, cheques, gift coupons, meal vouchers, credit note, advance adjustments POS device integration -cash drawer, pole display, magnetic stripe card reader, bar code, RFID Loyalty program definition by capturing the gift cards, benefits, registration details and so on |
Performance Optimization |
Lack of proper system for real-time MIS & Analytics |
Performance, operations and financial analytics Profitability and productivity analytics |
To ensure Compliance with Customs Laws & Regulations |
Frequently changing Laws & Regulations Lack of proper systems which help to execute processes in line with the regulations and laws |
Item tracking with Bill of Entry details through the life cycle Quota systems to map the regulations with the processes and ensure their abidance Customs related smart reports |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Batch management |
With multiple batches thorough verification of a batch is a laborious process |
Mbas batch management gives better control on lot, reverse tracking of lot. Batch posting and reversals -handle multiple batches |
Inventory Optimization |
Laborious inventory processes, tracking and traceability |
mbas optimizes Lot, bin and serial number based tracking. Inventory replenishment through re-order levels or manual requisitions mbas supports multi-level warehouse structure by providing accurate inventory visibility with mbas the warehouse structure can be modeled as per an organization’s requirement |
Inventory Optimization |
Optimize Inventory tracking |
Optimize Inventory tracking Lot, bin and serial number tracking Inventory replenishment through re-order levels or manual requisitions Barcode ticketing (EAN standards with UPC symbologies) and scanning of items Supports mullti-level warehouse structure by providing accurate inventory visibility Warehouse structure can be modeled as per an organization’s requirement |
Prescription verification of label to dispensed medication Complete billing and account receivables |
Billing process is not effectively. |
Billing process enables flexible options like cash, credit or debit cards, coupons or gift vouchers to suit the retail-specific needs. |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Business line-wise tracking of sales |
Poor Order Management Single Order Consisting of multiple specifications |
Sales orders specific to business lines Automatic creation of sales orders from master contract Item Specification to sales order |
Handling oil inventory |
Maintenance of WIP of crude oils in refinery plants |
With mbas users can maintain import and domestic raw material separately, with separate SKU’s for small packs Mbas allows users to maintain WIP for crude oil separately |
Optimizing production lead time |
Not being aware of the production lead time for each product |
mbas offers efficient tools to run planning and scheduling for each product, with automated production lead time it help users to thoroughly analyze every step of the production process, refine inefficient steps and remove unnecessary steps in the process |
Pain Areas |
|
Mbas Best Practice |
---|---|---|
Maintain high level of customer satisfaction and improve Customer retention. |
With mbas users can know best price and quotes, maintain long term contracts and agreements, offer incentives against their performance, Improve customer service & responsiveness, Available-to Promise and order confirmations, Drop shipments –delivery from vendor to customer directly |
|
Manage service requests and revenues. | Handling proper complaints and installation with proper service routings. Reduce complaint lead time and finish the service request on time. |
|
Manage incentives and rebates | Flexible quota defines, Flexible incentive and rebates disbursements |
|
Manage shortened sales cycles and higher sales force productivity. | Product management from creation to exclusion, Specific planning on seasonal items, Promotions planning & execution, Planning of prices, discounts and offers, Flexibility to add services with products |
|
Meeting Customer Demands viz., Low Price & Tight Delivery Schedules. | Proper order confirmation, Schedule Maintenance in Sales Order, Available to promise |
|
Maintain proper inventory management | Accurate inventory visibility, Efficient Warehouse Management supporting multi-level W/H structure, Configurable item properties ,Inventory Replenishment Planning –Order Methods, Order Qty etc, Seamless integration amongst different functions and business processes |
|
Managing Purchase Lead Times. | With mbas users can select vendors through periodic evaluations on performance. Centralized\de-centralized\semi-centralized purchasing, Long term contracts and agreements after negotiations Demand consolidation and optimization |
|
Efficient Decision Making on Critical issues | Mbas on real-time basis updates accounts and other key processes on invoicing, returns etc., Analytics with built-in KPIs to monitor real-time performance on multiple dimensions, Consolidation –multi-company, multi-location scenarios |
|
Returns handling | Mbas offers Flexible Sales return advice with replacement, rework and refund facility |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Maintaining production quality |
Missing consistent quality checks. Quality inspection Difficulty in trouble shooting |
Mbas offers Incoming quality checks for raw materials, Quality checks for sub-contractors production and Stage wise checks during production |
Optimizing production lead time |
Not being aware of the production lead time for each product |
mbas offers efficient tools to run planning and scheduling for each product, with automated production lead time it help users to thoroughly analyze every step of the production process, refine inefficient steps and remove unnecessary steps in the process |
Efficient inventory management |
No clear visibility on raw materials Inefficient order methodologies for items Stock at subcontractor level is unknown |
With mbas users can efficiently maintain shop floor items, variant specific stock details, can have a clear visibility of subcontractors stock and maintain ROL’s for items. |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Order wise scrap calculation |
No proper mechanism to record production- scrap on the shop floor |
On daily production entry scrap also need to be given for order Wise scrap generation qty |
Inventory Management |
Non availability of integrated inventory data |
mbas using MPS and MRP tools gives a complete inventory view to the users all of which can be flexibility accessed using inventory reports. |
Sub Contracting operation and its tracking |
Tough to track subcontractors stock Cost of material lying with the sub contractor |
mbas will provide the subcontracting operation status, and vendor end inventory record in a moment |
Order Costing |
Inaccurate and time consuming costing |
With mbas users manage item costing along with production |
Pain Areas |
|
Mbas Best Practice |
---|---|---|
Expired products traceability | With mbas users can track and trace expiry of each and every item |
|
Optimizing Delivery Lead Time | With mbas users can do Proper selection of vendors through periodic evaluations on performance, can maintain long terms contracts & agreements and do drop Shipments |
|
Quality management | mbas offers quality checks for items at every stage adhering to standards and ensuring compliance |
|
Managing Product Variants | With mbas different variants for a product can be created with easier tracking of each item variant |
|
Inventory Management | With mbas users can maintain: inventory control over multiple locations Expiry dates for perishable stock Different grades for inventory stock |
|
Manage Products with shorter life cycle | Mbas offers: Product management from creation to exclusion ,Seasonal Items Promotion and Pricing and discounts |
|
Logistics management | Mbas offers Fleet tracking, Unit Commissioning, Preventive maintenance and managing goods while transit |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Optimizing production lead time |
Not being aware of the production lead time of each product |
mbas offers efficient tools to run planning and scheduling for each product, with automated production lead time it help users to thoroughly analyze every step of the production process, refine inefficient steps and remove unnecessary steps in the process |
Inventory management |
Inventory management is tough due to continuous production |
mbas helps to get the inventory status at any time expenses planning help to procure the material on the required time to fulfill the requirement with mbas know the status of inventory anytime |
Process Parameter tracking |
laborious paper based parameter (temperature, pressure, etc) tracking which is prone to errors |
Wherever and whenever required mbas prompts for process parameters and saves all the data. In case a quality issue arises it verifies standard to actual parameters and alerts users on the deviation. |
Optimum Capacity utilization |
On normal scenario capacity and load calculation is time consuming job |
mbas production have facility to plan the production and provide the capacity condition for optimum utilization |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Supply Chain In Efficiency |
High Procurement Lead Time Poor Order Management |
Mbas offers Better Order Management Techniques Shorten Purchase requisition to order lead time Provides full supply chain visibility |
Optimizing production lead time |
Not being aware of the production lead time of each product |
mbas offers efficient tools to run planning and scheduling for each product, with automated production lead time it help users to thoroughly analyze every step of the production process, refine inefficient steps and remove unnecessary steps in the process |
Efficient inventory management |
No clear visibility on raw materials No specific ordering methodology for items. Unknown subcontractor stock |
Mbas offers Lot identification & serial number applicability With mbas users can maintain variant specific stock details, subcontractor stock details, ROL’s for items |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Key information such as financial and production details |
Lack of proper integration between Manufacturing and Head Office Mismatch of information generated by production plants sent to the corporate office |
mbas MIS, helps top management to get key information from its plants on a daily basis |
Lack of visibility of the shop floor load |
Lack of computerized system to see the load |
Work center load graphs and reports for better analysis of the load at shop floor any time and without any delays to assist in faster decision making |
Little flexibility in scheduling – not allowing to determine where potential problem existed and to create corrective solutions on the production line before slowdowns occurs |
No system to identify bottleneck resources Not able to reschedule the remaining work |
With mbas Planning Module can check the load on bottleneck resources and can Reschedule process to arrive at the revised dates of production |
missed Delivery dates because of lack of inventory control |
Poor Supply Chain Planning |
With mbas Managers have the most current inventory available so that they can set the most competitive pricing that ensures profitability as well |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Inaccurate demand forecasting |
Lack of Demand Visibility from the Retailers |
Mbas offers: Demand forecasting at the lower/lowest organizational entities, consolidated demand at the various hierarchy of the distribution. |
Poor Cash Flow |
Cash blocked in non-planned stock piled. Poor Credit Management. Poor procurement planning |
With mbas users can maintain appropriate inventory levels, through Replenishment Planning, Procurement planning based on Demand Forecasting Helps keeping strict credit monitoring and control, for individual customers and customer types/groups. Credit monitoring and control is also available for the Sales Region. Efficient procurement planning ensuring minimum level of the desired stock. Thus reducing the capital blocked in the excessive inventory. |
Capital Trapped in Buffer Inventory |
Buffering inventory in anticipation of the customer demand. Inability to manage the drop-ships from vendor to the customers. Improper Inventory Planning. |
mbas ERP supports the direct drop-shipment from the vendor’s location to the customer, emanating the transit storage at the organization warehouses. This makes the cash flow faster and reduces the Inventory carrying costs. Effective Inventory planning, with proper replenishment strategies (ROL, Min/Max, Ordering Methodologies viz.) reduces the inventory carrying cost and ordering costs. Back Ordering process helps users to directly route actual demands for immediate sourcing, hence reduces inventory pilling. |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Optimizing production lead time |
Not being aware of the production lead time of each product |
mbas offers efficient tools to run planning and scheduling for each product, with automated production lead time it help users to thoroughly analyze every step of the production process, refine inefficient steps and remove unnecessary steps in the process |
Efficient inventory management |
No clear visibility on raw materials Inefficient order methodologies for items Stock at subcontractor level is unknown |
With mbas users can efficiently maintain shop floor items, variant specific stock details, can have a clear visibility of subcontractors stock and maintain ROL’s for items. |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Balancing supply & demand |
No Integrated plan to achieve Business Goals |
With mbas users can forecast and plan for anticipated end products. |
Identifying critical resources |
Planning not based on bottleneck Process |
RCCP (rough cut capacity planning) to identify the bottleneck resources and Plan accordingly will identify the bottleneck process |
Tracking production lot |
Inaccurate methods to track the produced lot which in turn reduced the product quality |
mbas offers Effective lot tracking & serial number tracking to differentiate the produced lots. |
Engineering change management |
Improper change management that may lead to poor customer satisfaction |
mbas offers ECR and ECO to keep track of all the engineering changes |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
End to end supply chain collaboration |
Lack of proper systems that would extend your business processes with that of the customers\suppliers\partners. Too much dependency on manual\ conventional methods of communication. Lack of clarity on customer expectations |
Web-based Solution Access on Internet anywhere, anytime Vendor log-in to view RFQs and publish quotes, view orders and speed up shipments Customer log-in to float RFQs and view quotation, place orders and view stock and order status EDI to connect with customer\vendor business processes Zero dependency on paper work Collaborative planning with vendors and customers for efficient distribution |
Manage Products with Shorter Life Cycles |
Lack of awareness on product life cycles. Poor focus on Value-Added Services. |
Mbas offers: Product management from creation to exclusion Specific planning on seasonal items Promotions planning execution Planning of prices, discounts and offers Product performance and profitability analysis Support custom packaging, product labeling etc as per customer requirements Flexibility to add services with products |
Efficient inventory management |
No clear visibility on raw materials Inefficient order methodologies for items Stock at subcontractor level is unknown |
With mbas users can efficiently maintain shop floor items, variant specific stock details, can have a clear visibility of subcontractors stock and maintain ROLs for items. |
Managing Purchase Lead Times |
Lack of collaboration with vendors. Improper planning. Lack of control on vendor. |
Proper selection of vendors through periodic evaluations on performance Centralized\de-centralized\semi-centralized purchasing Long term contracts and agreements after negotiations Demand consolidation and optimization Drop shipments |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Work center loading Ex: furnace) |
Standard times not maintained Capacity factor for items unknown Dates are not calculated based on bottle neck machine capacity |
Furnace kind of machines maintained as dense WC Work center load as well capacity occupied is known Planning streamlined for bottle neck machine |
Maintenance for critical equipments |
Maintenance only on break downs No planning for spare parts No information of time taken for maintenance |
Machine maintenance history Schedules of preventive and predictive maintenance MTBF information Spare parts planning |
Efficient inventory management |
No clear visibility on raw materials Inefficient order methodologies for items Stock at subcontractor level is unknown |
With mbas users can efficiently maintain shop floor items, variant specific stock details, can have a clear visibility of subcontractors stock and maintain ROL’s for items. |
Production cost calculation |
Unknown RM consumption Labor information not tracked Sub-contractor stock is not known |
With mbas users can map overheads for work centers, capture consumption of raw materials in SFR. With mbas users can achieve Labor and overhead reporting, Sub-contracting service cost information. Total cost of production calculated while settling production order for the machinery produced |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Need is greater than capacity |
Poor planning and lack of tools to identify idle resources. |
Mbas offers users with better planning , Reconciliation of Order & Realization of Production Order, Optimize operations ,meticulous planning and through work center Load graphs –where in idle resources can be checked |
Optimizing production lead time |
Not being aware of the production lead time of each product |
mbas offers efficient tools to run planning and scheduling for each product, with automated production lead time it help users to thoroughly analyze every step of the production process, refine inefficient steps and remove unnecessary steps in the process |
Efficient inventory management |
No clear visibility on raw materials Inefficient order methodologies for items Stock at subcontractor level is unknown |
With mbas users can efficiently maintain shop floor items, variant specific stock details, can have a clear visibility of subcontractors stock and maintain ROL’s for items. |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Forecasting |
Lack of accuracy, increased time consumption, higher probability of errors |
Mbas provides the actual data in short span of time and user can correct forecast with the help of smoothening factors in last periods |
Foreign currency handling |
Difficulty in maintaining multi currency transactions |
mbas support multiple currency transactions so there is no need to put extra effort to managing these |
Export Process |
High level of complexity in handling high volume export |
mbas export integration helps to reduce the documentation time, record information in standard forms thereby avoiding duplication of work |
Inventory Management |
Increased time consumption, poor data integration, higher probability of errors |
mbas through MPS and MRP tool gives a complete picture of the inventory to the planner at any time with the help of inventory reports |
Pain Areas |
|
Mbas Best Practice |
---|---|---|
Excess/redundant stock or stock shortages | mbas offers – Real-time stock status Stock aging report Expected deliveries from suppliers Pending/Open sales orders |
|
Fluctuating customer demand | mbas Available-To-Promise feature provides the required quantities for a future date |
|
Managing numerous SKUs | mbas offers provision to - Define SKU/variants and track stock at SKU level Create sales order at SKU level |
|
Uncertain cash flow due to poor credit management | mbas Credit Management feature allows tracking pending receivables and payables |
|
Managing consignment stock at retailer’s location | mbas Consignment-OUT Management feature allows maintenance and tracking of consignment stock |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Respond quickly to changing customer demand |
No integrated plan to achieve goals Inaccurate forecast |
Mbas offers – o SOP to integrate plans o Demand Planning & Forecasting |
Reduction in production lead time |
No input output control Improper management of orders No control on shop activities Not maintaining standard times |
Mbas offers – o Automatic lead time calculation based on routing o Capacity calculation based on finite or infinite capacity o Scheduling option for forward and backward o Production order rescheduling |
Efficient inventory management |
No tracking of stock of raw materials No order methodologies for items Subcontractor stocks not known |
Mbas offers – o Maintenance of shop floor items o Maintenance of stock details (variant specific ) o Maintenance of subcontractor stock details o Maintenance of ROL’s for items |
Pain Areas |
|
Mbas Best Practice |
---|---|---|
Improper inventory visibility throughout the supply chain |
Mbas offers – Multi-level warehouse structure Configurable item properties (location, lot, serial no., expiry etc) |
|
High inventory build-up due to inaccurate order scheduling |
Mbas offers – Proper order confirmation Order scheduling in sales order Available-To-Promise feature |
|
Maintaining high customer satisfaction levels |
Mbas provides provision to - Offer best price and quotes Maintain long term contracts and agreements Improve customer service & responsiveness Drop shipments |
|
Manage sales quotas definitions and incentive disbursements |
Mbas offers – Flexible quota definition Flexible incentive and rebates disbursements |
|
Sales Returns Management |
Mbas offers flexible sales return advice with replacement, rework and refund facility |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Customers requiring different packaging for the same item |
Lack of awareness on product specifications |
With mbas users can maintain separate recipes for production and Packaging |
Managing items with different concentration levels |
Lack of proper recipe management |
mbas offers recipe management taking potency factor into account. with mbas users have the flexibility to issue items with different concentration factors if the required concentration is not available |
Efficient inventory management for shorter shelf life |
Improper administration of warehouses Poor inventory valuation methods |
Accurate inventory visibility Multi-level warehouse structure Inventory issues based on FIFO strategy |
Handling customer complaints Lack of integration between departments |
Lack of lot recall system Lack of metrics & tools that aid in decision making |
mbas offers flexible reports, one of which is a LOT recall report which identifies lots of raw materials for a specific finish good Real-time update of accounts and other key processes like invoicing, returns etc |
Meeting Customer Demands viz., Low Price & Tight Delivery Schedules |
Lack of control on operation and costs Poor production planning |
Available-to-Promise and order confirmations Accurate data for manufacturing decisions through planning on machine utilization, online WIP components costing |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Product group level forecasting |
Lack of accuracy, increased time consumption, higher probability of errors |
mbas planning is equipped with production item wise/ item group wise planning and forecasting |
Capacity Leveling |
Proper capacity calculations is not possible |
mbas supports capacity leveling, forward and backward scheduling for smooth production |
Product costing |
Difficulty in manual cost calculation |
mbas has full fledged costing module which calculate direct cost, labor cost and overhead cost automatically |
Batch information tracking |
Limitation in tracking batch information of raw materials and finished goods |
mbas support batch information with traceability in inventory, production, quality and sales |
Pain Areas |
|
Mbas Best Practice |
---|---|---|
Collaboration for proper planning and distribution |
Collaboration with customers and suppliers on planning, distribution and purchasing. Evaluation of vendors and suppliers. |
|
Enhance delivery capabilities | Mbas offers planning for procurement and distribution, checks on delivery dates and time, demand classification and consolidation |
|
Timely replenishment of inventory | mbas supports on time delivery of goods, tracking of goods and replacement of goods |
|
Competitive pricing strategies for products | Mbas supports different pricing strategies and defining contractual prices |
|
Managing of consignment stock | Mbas offers vendor managed inventory, efficient replenishment and proper tracking of inventory |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Net Sales Requirement for an item Closing Stock at different locations |
Lack of proper integration between different Sales depot Lack of integrated data thereby not giving a concrete information |
Available-To-Promise (ATP) and order confirmations Centralized Planning for different sales depots Item measure feature to give the exact stock irrespective of pack size |
Finished Goods transfer with multiple packing sizes and hence difficulty in batch tracking |
Improper administration of item measures at location level Poor lot/batch recall methods |
Accurate planning & production of finished goods (lot wise) as per packaging recipe Lot recall report showing the lot of raw materials used |
Handling Customer complaints Goods received at factory without PO number |
Lack of Lot recall system Lack of integration between Purchase and Inventory department |
mbas offers flexible reports, one of which is a LOT recall report which identifies lots of raw materials for a specific finish good GRN with respect to PO only |
Huge volume of invoices, its reconciliation with deliveries |
Lack of integration between finance and inventory departments |
Updating of accounts payable and receivables in finance as per materials received or sold |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Maintaining production quality |
No proper quality checks Difficulty in trouble shooting |
Incoming quality checks for raw materials Quality checks for sub-contractors production Stage wise checks during production |
Reduction in production lead time |
No input output control Improper management of orders No control on shop floor activities |
Automatic lead time calculation based on routing Capacity calculation based on finite or infinite capacity Scheduling option for forward and backward Production order rescheduling |
Efficient inventory Management |
No tracking on stock on RM No order methodologies for items Subcontractor stock is unknown |
Maintenance of shop floor items Maintenance of stock details variant specific Maintenance of subcontractor stock details Maintenance of ROL’s for items |
Order is greater than Capacity |
Unable to identify idle resource Poor planning |
Better planning , Reconciliation of Order & Realization of production Order , Optimize operations , meticulous planning and through work center load graphs -idle resources can be checked |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Optimum utilization of production resources, unable to capture cost of production details |
No information on production orders Not able to reschedule Labor / over heads cost unknown |
Optimum utilization of manufacturing resources Monitors new product development Detailed production cost calculations |
Maintenance of QC results and pegging details |
No incoming inspection No procedure for in-house QC No process to track SPC No importance for scrap details |
Test plans as per production process History of deviation note Process capability measurements Reduction of scrap |
Maintenance for Critical Equipments |
Maintenance only on break downs No planning for spare parts No records of time taken for maintenance |
Machine maintenance history Schedules of preventive and predictive maintenance MTBF information Spare parts planning |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Every plant has its own systems, platforms and processes |
Lack of proper integration between various plants |
Mbas helps in Streamlining transaction systems across plants thus resulting in better quality |
Delayed information reporting to corporate office |
Too much time consumed in compiling data and analysis |
mbas BI solutions helps in instant flow of information to the top management without any delays with the latest updated data |
Losing money because of constant purchasing oversights and no reliable pricing structure |
No updated system to analyze the pattern of the last purchases No scientific methods followed like EOQ for purchasing resulting in more inventory |
mbas helps in overall price reduction on purchased items through better negotiations on the basis of Purchase Price Variance report |
To manage Item specifications with SKUs with the changing market demands Unable to trace the ingredients lot numbers when customers complaints are coming |
Poor Supply Chain Planning Current system is unable to manage SKUs and specifications as an inherent property of the item Unable to provide any corrective measures for the complaints |
Mbas offers Planning module to support Items with SKUs and specifications Lot recall report for tracking the ingredients lot number to identify root cause |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Optimum use of resources |
Production planning takes long hours |
mbas help planning of resources for optimum uses and exact scheduling |
Production cost reduction |
Production cost are not properly captured |
Mbas offers end-to-end automation and integration with all departments |
Inventory management |
Poor inventory management |
mbas through MPS and MRP tool gives a complete picture of the inventory to the planner at any time with the help of inventory reports |
Recyclable Product management |
Recycle product have to be managed separately thereby causing extra caution and time consumption |
mbas has recyclable product tracking and proper inventory management so history can be generated at any time for recyclable product and can be used in manufacturing |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Raw material planning (Mother Hallow) |
RM with all dimensional variations details not available Mechanical and chemical properties of items are not maintained |
Stock details of raw materials with dimensional variations maintained Stock valuation is carried out separately for dimensional variation items Automatic raw material suggestion from the System based on size, mechanical and chemical properties |
Work center loading ex. furnace |
Standard times not maintained Capacity factor for items not known Dates are not calculated based on bottle neck machine capacity |
Furnace kind of machines maintained as dense WC Work center load and capacity occupied is known Planning streamlined for bottle neck machine |
Maintenance for Critical Equipments |
Maintenance only on break downs No planning for spare parts No information of time taken for maintenance |
Machine maintenance history Schedules of preventive and predictive maintenance MTBF information Spare parts planning |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Too much money spent to meet customer commitments |
Lack of collaboration with customer Inaccurate data |
Available-To-Promise (ATP) and order confirmations Sound planning to give accurate data |
No clear visibility of inventory |
Lack of net requirement planning No EOQ/FOQ methods followed |
Material Planning based upon Net requirement Supports EOQ/FOQ practices to optimize inventory level |
More storage required for inventory/WIP/finished goods |
No control at shop floor for the items lying Improper planning |
Only required quantity is taken from the inventory for production, thus reducing waste at shop floor Process orders as per planning to avoid excess material lying at WIP |
Increased capacity required but unable to justify the new investment |
No concrete long range planning in accordance with production resource |
Resource Planning for longer periods in accordance with the production resources |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Quality Checking |
Too many specifications |
Mbas offers better handling of quality related issues |
Efficient Capacity Planning |
Lack of Capacity Planning at every level |
mbas support Resource Planning, RCCP and CRP effectively |
Scrap Analysis |
Not including scrap |
Scrap factor can be defined at the Level of BOM as well as BOM item. Efficient Tracking of scrap |
Design Change |
No control on engineering change |
mbas through ECO feature addresses any design change of products |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Maintaining production quality |
No proper quality checks. ¾Skipping the inspection process Difficulty in trouble shooting |
Incoming quality checks for raw materials Quality checks for sub-contractors production Stage wise checks during production Installation & Commissioning |
Reduction in production lead time |
No input output control Improper management of orders No control on shop activities Not maintaining standard times |
Automatic lead time calculation based on routing Capacity calculation based on finite or infinite capacity Scheduling option for forward and backward Production order rescheduling |
Efficient inventory Management |
No tracking on stock on raw materials No order methodologies for items Subcontractor stock is unknown |
Maintenance of shop floor items Maintenance of stock details variant specific Maintenance of subcontractor stock details Maintenance of ROL’s for items |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Manage Products With Shorter Life Cycles |
Lack of awareness on product life cycles. Poor focus on Value-Added Services. |
Product management from purchasing to sales SKU Variants Management Specific planning on seasonal items Promotions planning executionPlanning of prices, discounts and offers Product performance and profitability analysis Flexibility to add services with products |
Efficient Inventory Management |
Poor inventory planning. Poor coordination across sales, purchase, inventory processes. |
Accurate inventory visibility Configurable item properties (lot, serial no.) Inventory Planning As per Forecasting Seamless integration amongst different functions and business processes |
Customer History Management |
Lack of Historical data of customers |
Efficient customer data management Promotion of new scheme though SMS/ Mails Online customer order Management Customer data management for After sales service |
Differentiate Business from Competition |
Lack of Point-of-Sale system. Poor customer service. |
Touch screen menus with graphical user interface, Microsoft OPOS compliant Apply price, promotions, discounts and taxes to items Flexible tender options -cash, credit card, debit card, cheques, gift coupons, meal vouchers, credit note, advance adjustments POS device integration -cash drawer, pole display, magnetic stripe card reader, bar code, RFID Loyalty program definition by capturing the gift cards, benefits, registration details and so on |
Performance Optimization |
Lack of proper system for real-time MIS Analytics |
Performance, operations and financial analytics Profitability and productivity analytics |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Demand Planning |
Incorrect Sales Forecasting Difficulty in Demand Consolidation |
Efficient Sales Forecasting Monitors new product development Master Scheduling and MPS |
Production and Resource Planning |
Non Flexible Production Plan Loading and unloading |
Optimum utilization of manufacturing resources Production Plan with Capacity Checks every level Tracking of quality checks at each level Process capability measurements Improves work force productivity Improves Sales |
Integration |
Non integrated IT approach |
Providing Graphical user interface Cross function integration with other modules/departments Easy tracking of Man material and machine Manufacturing and supply chain Integration |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Identifying necessary tools including the next die and different die sizes |
No tracking of tools and material Unable to issue tools Operation not streamlined Inaccurate production cost calculations |
Able to track tools and material for Production Issues and receipt across the sub organization Tracking of operations through status Accurate Production cost calculations |
Market demands with higher Customizations & Engineer To order Capabilities |
Unable to meet market demands |
Improve Manufacturing flexibility and Operational excellence Streamline current operations Speed design of simple, reliable machinery Improve customer loyalty and retention |
Maintenance of pressroom |
Maintenance only on break downs No planning for maintenance items No information of time taken for maintenance |
Schedules of preventive and predictive maintenance Spare parts planning |
Pain Areas |
Why do Companies fail? |
Mbas Best Practice |
---|---|---|
Centralization of Distributed network |
Sudden changes in market condition forcing the user to find new distribution channel thus creating problem in increasing order-to-shipping time |
Centralized planning to consolidate the demands at a single point for better demand and supply planning |
Standardization of business processes across various locations |
Every plant has its own Systems & platforms |
Streamlined transaction systems across plants |
Little flexibility in scheduling Huge volume of invoices, its reconciliation with deliveries |
Not allowing to determine where potential problem existed and to create corrective solutions on the production line before slowdowns occurs Lack of integration between Finance and other departments |
RCCP and CRP helps in making visible the bottleneck resources which allows flexibility in Planning and scheduling Real-time update of accounts and other key processes on invoicing, returns etc |
Losing money due to constant purchasing oversights and no reliable pricing structure |
Unable to select the suitable quotation in terms of price, payment terms, delivery terms etc |
Better analysis of the vendor through Quotation evaluation and Quotation comparison |