eXensys Process Manufacturing offers an adaptive methodology to automate the recipe-based industries by enabling them in formulating new products, managing variability, optimizing capacity and driving continuous process improvement to meet global demands in a short span.

 

 

  Supports flow, batch and contract manufacturing

  Formula / recipe management, shelf life management

  Operation wise process control, quality inspection instructions, process

   parameters definition

  Potency and assay of raw materials

  Interface with real time system like DCS, SCADA, etc.

  Batch or lot tracking

  Material and capacity planning through MRP and CRP

  Available To Promise (ATP) calculation for sales support

  Graphical representation of work center load leveling and process order

   scheduling

  Shop floor prints like route card, job card and job list per work center

  Downtime analysis with different operation times

 

 

  Increases production efficiency and tight control over ingredients and processes

  Minimizes manufacturing lead times and meets customer demand with flexible

   scheduling options

  Provides real-time visibility into quality at every phase of production including

   raw materials, intermediates, byproducts, sub lots and final products

  Immediate generation of compliance reports

  Controls utilization of manufacturing resources for optimum performance

  Gains detailed cost analysis capabilities

  "What-if" scenario analysis

  Provides simulated yield results for scale up and down of different batches

 

 

  Dynamic production process modeling

  Management of byproducts, co-products and recycling materials

  Consolidating demand through Master Scheduling from various sources like

   sales order, production plan, new projects, etc.

  Centralized supply planning integrated with Distribution Requirement Planning

   (DRP)

  Master Production Scheduling (MPS) and RCCP to finalize the independent items

   requirements

  Process parameter management

  Reservation system provided for hard and soft allocation

  Forward and backward scheduling

  Process order rescheduling, reprocess order generation based on shop floor

   reporting and new order

  Action and exception messages in Material Requirements Planning (MRP) to

   optimize the material plan

  Back flushing of raw materials based on shop floor reporting

  Control point reporting for continuous production

  Labor & process parameter reporting

  Activity elements to capture overhead cost

  Multiple lot issues & receipts

  Maintenance of process parameters for routing

 

 

  Process management for monitoring the process parameters

  Packaging type recipe

  Buying of manufacturing items in Firm MPS to resolve in-house capacity

   constraints

  Process orders can be generated for reprocess type

  SOP to balance demand and supply

  Resource planning to check whether resources are available to meet the SOP

  Rough cut capacity planning to check the availability of critical resources

  Sub contracting operations to reduce the capacity constraints

  MRP to explode the recipe, net quantity finalization, lead time calculation

  ECR & ECO to keep track of engineering changes