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Is your company carrying an invisible burden?

 
It goes without saying that in the manufacturing industry, the last thing you would want to happen is failing to meet a promised delivery date. However, daily operations are full of unexpected problems, such as inventory shortages, machine breakdowns, or labor capacity constraints.
 
When such problems occur, the planning department must stop their current operations to rework the production schedule, the production department is required to put in overtime, and the sales department needs to notify the customers as soon as possible and apologize for the delay. All of this comes at the expense of the company’s time and credibility.
 
On the surface, it seems that issues like these can be resolved with increased effort on the shop floor. Overloading resources and relying on employees to work harder is just masking the real causes of obstacles in the production process, such as a flawed production plan or lack of visibility.
 
This is where a data-driven system like Beas Manufacturing comes into place, to eliminate the invisible burden in your company.
 
 

MRP plans for materials

 
MRP (Material Requirements Planning) is essential for production planning. (Click here to read about MRP in SAP Business One.) With MRP, planning tasks that previously required hours of manual effort to complete can be done with the push of a button. It also makes it possible to maintain adequate inventory levels and prevent critical stockouts.
 
Results of a MRP calculation identify which products or components are at risk of being delayed. It helps the person in charge make informed decisions about schedule adjustments, request shorter supplier delivery times, and negotiate with customers.
 
 

MRP2 plans for capacity

 
Besides materials, it is essential to manage labor and machine availability for successful production. This can be done by using MRP2 (Manufacturing Resource Planning). While MRP ensures that the right materials are available, MRP2 ensures that the factory has the capacity to produce them, keeping the production schedules realistic.

In the screenshot above, we see a MRP2 calculation result in Beas Manufacturing. As shown in this example, the total demand for the automatic assembly machine will exceed its configured capacity by 7 hours within the specified 6-day period.
 
By visualizing future workload for both personnel and machines, measures can be taken to eliminate chronic overtime and holiday work. This also represents a paradigm shift from operational planning that is dependent on the knowledge and experience of specific, key individuals, to data-driven planning.
 
 

Accurate production management will dramatically transform your shop floor

 
Improving the accuracy of production management extends far beyond simple metrics, like machine utilization. It opens up the possibility of transforming a shop floor that operates under constant pressure to prepare for and manage unexpected problems, into a more refined one that is based on reliable data. After implementing Beas Manufacturing, three significant changes will occur in your factory.

1. Increased productivity: Planning time is reduced. Chronic overtime, waiting for materials, and waiting for instructions on the shop floor are eliminated, resulting in increased productivity across the company.
2. Key person risk mitigation: The transformation of individual know-how from experienced personnel into a shared organizational asset. This eliminates the pressure put on specific individuals and allows the entire team to work according to an optimized plan, increasing organizational stability.
3. Building trust: An increased rate of on-time delivery will help build customer satisfaction, which in turn creates stronger brand trust and loyalty. It will make people say, “you can rely on this company, since they will get the job done, no matter what”.

Maintaining minimum inventory and ease of operation on the shop floor is directly linked to the company’s strength and stability, while optimization of production capacity builds on that, creating a reliable foundation that enables focus on the work that really matters.
 
If you are interested in learning more about Beas Manufacturing MRP and MRP2, please feel free to contact us for more information.