How to implement ERP in the hottest process manufa

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How to implement ERP in process manufacturing industry

many ERP experts believe that ERP in process manufacturing is relatively simple, which is mainly reflected in the small variety of raw materials and simple product structure in process manufacturing industry. Therefore, its BOM structure is simple, and the MRP plan is simple and easy to implement, so that the production scheduling process, cost accounting and inventory control are relatively easy. People who hold this view are mentioned in their books on ERP principles and applications. Of course, this kind of ease is relatively discrete manufacturing, especially for complex discrete manufacturing

I think: in terms of the comparison of the difficulty degree between discrete manufacturing and process manufacturing, the comparability is not much. In terms of product attributes and product structure, discrete manufacturing is easier to achieve precise management control than process manufacturing, so it is easier to implement ERP. The complexity of discrete manufacturing is mainly due to the large number of parts and components, resulting in the huge BOM. There are many material plans for procurement, production and inventory to be controlled. Poor balance control will lead to material backlog or production waiting. Of course, there are other problems

however, in terms of the following factors, process manufacturing is more complex than discrete manufacturing, more difficult to manage and control, and more difficult to implement ERP:

1. Product structure: discrete manufacturing uses a tree hierarchical BOM, which is a static fixed product structure. No matter how many layers the BOM has, its material quantity, material model, and production process are fixed, and there may be a few substitutes, But the overall is fixed. If there are changes, the design needs to be modified. However, the product structure of process manufacturing cannot be described by the hierarchical tree structure, especially the complex process manufacturing needs to use the chain structure (single chain or multi chain), which defines the production route required in the whole process of product manufacturing as a process specification. Each process specification has various production stages. This production stage is a logical stage, and the thickness of the stage can be determined according to the specific production situation, management needs It depends on the means of measurement and statistics. A production stage can correspond to multiple stages at the same time, or multiple stages can correspond to one stage, which is called V20. Test bench return: manually return to the initial position of the experiment at the highest speed, A-type and X-type structures. Some materials may need to be recycled and reprocessed from the later stage to the previous stage. The processing direction of materials cannot be completely fixed in advance

there may be multiple intermediate or final outputs, which we call joint products and by-products. It is complex to accurately determine the quantity of joint products or by-products. Some people will say: it's OK to take an average or approximate value, but in a highly competitive market environment, if the error of each combined product volume is 0.5%, the whole error will be large. We know that many process manufacturing industries belong to capital intensive flow production, and China's tens of millions of oil refining and steelmaking; 800000 tons of ethylene; 1.5 million ton beer enterprise.... Wait, an error of 0.5% will be a big error. This means that we can't do fine production at all. To accurately determine the volume of each co product, ERP is powerless in complex process manufacturing, and MES is needed. The whole production process is a dynamic process. The output, material characteristics, and even material processing routes are affected by fluctuations in raw material composition, operation, processing temperature and pressure, equipment, and so on, and are unpredictable. Discrete manufacturing does not have this problem, so it is easier to plan accurately, timely and in advance

process manufacturing requires great flexibility to deal with this problem

2. The measurement of process Manufacturing in the whole process of production and operation may be very complex. The measurement unit of material conversion in the process of material storage, transportation and processing may be as follows:

there is no conversion relationship, such as pigs are expressed in kilograms or heads, steel is expressed in tons or lengths, and paint is expressed in kilograms or cans. How many kilograms are converted into how many bundles, or even if there is a conversion rate, the relationship is complex, such as gallons when purchasing, tons when storing, barrels when shipping, quarts (1.14 liters) during production, ounces when consuming, etc. The material conversion of each batch is related to the material characteristics

efficiency relations, such as material composition, concentration, moisture, and nutritional components of some foods. That is, efficiency is closely related to weight (volume) and cost with logistics composition, concentration and other indicators

multiple packaging units, packaging can occur in any process of material purchase, storage, production and sales, and the packaging units can be boxes, bottles, bundles, tanks and containers, etc., which need to get the visibility of the inventory of large quantities of goods in various containers and packaging combinations. It is necessary to know which bottles, cans and boxes the materials of a certain batch number are packed in

MHU problem of material storage unit

3 In the process of process manufacturing, the tracking of material characteristics is very important. Due to the storage of materials in process production, the mixing and decomposition of production process, tracking materials is not as straightforward as discrete manufacturing, so batch tracking is more difficult than discrete manufacturing. Batch tracking is very important, which provides the most basic basis for the analysis and control of product safety, quality, storage life, cost and other factors

4. Due to the material reaction mechanism, equipment, environment, operation and other reasons, the process manufacturing process has great volatility, so the process formula (recipe or formula) needs to be dynamically adjusted. Discrete manufacturing does not have such fluctuations

the rotation center of the discrete swing arm is connected to the input shaft of the gear set; The mandrel of the tooling is connected with the output shaft of the gear set; The fracture detection probe is set at the position of the corresponding tooling. The manufacturing process emphasizes the planning in advance, while the process manufacturing strengthens the tracking and adjustment in the adjustment. Discrete manufacturing can achieve accurate planning, while the accurate planning of process manufacturing is impractical, which mainly depends on real-time tracking, control and correction. Because the process manufacturing process is continuous, the downtime loss is huge according to the sample length, and inventory control and fine production are more difficult than discrete production

according to our survey, the proportion of MRPII in the enterprise informatization of global process manufacturing companies is far less than that of discrete manufacturing. The performance of MRPII in discrete manufacturing is obvious to all. JIT and other methods have been successfully implemented in discrete manufacturing industry

in this way, we can see that the implementation of ERP in process manufacturing industry is more difficult than that in discrete manufacturing industry. But on the other hand, we also see that there is still a lot of room for ERP in the process manufacturing industry, and there is still a great potential to tap the management benefits of the process manufacturing industry. (end)

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