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