 Solution
Components |
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| Costing |
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The Costing module provides sophisticated, precise
calculations based on all factors that affect product
cost - including labor, overhead, loss, and more.
It reformulates the mixtures to meet the desired
target costs, and generate a detailed analysis of
all types of cost-related data instantly. With BatchMaster,
you can rely upon advanced tools, coupled with a
disciplined methodology, to closely monitor and
control your costs, without sacrificing quality. |
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Make decisions on prices for end items
to assure profitability given fluctuations
in sub- formulas
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Product cost analysis to evaluate each
formula in different sizes or containers
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Batch-sizing based upon cost, size or
density or costs per unit weight or unit
volume
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Roll-up intermediates to update sub-formula
costs in overall costs using Last, Standard
or Average costs
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Update labor and overhead
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Adjust for formula loss to increase accuracy
in costing, matching against historical
yields
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Update finished goods to reflect changes
in inventory materials costs using Last,
Standard, Average or Base
Cost or Market Price
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Change weight of formula in finished
goods
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Rely upon reports for detailed product
cost, formula cost summary and product cost
analysis to compare costs
for finished goods in different sized
containers
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| Formulas |
| At
the heart of your Product Development Lab is your
ability to design and manage all your formulas.
You need an audit trail on your experimentation
to take the mystery out of success and make it repeatable.
BatchMaster supports multi-level formulas and easy
material substitutions. Experimentation with new
formulas should be just as easy as the maintenance
of your tried-and-true formulas. BatchMaster is
a formula-based software and is not BOM-based, with
ingredients added in prescribed proportions measured
by either weight or volume. |
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Unlimited inventory materials, intermediates,
units of measure
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Unlimited manufacturing instructions
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Formula revision history
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"Where - used" capability by material,
formula or QC control
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Size by weight, volume or physical property
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Material substitutions, if necessary
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"What-if" analyses by formula/product
container cost or physical property
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Reformulation by target value of physical property
or yield
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Yield analysis capabilities
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By/Co- products calculations
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Loss factors by ingredient
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Weight, volume, density of materials
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Costs for materials, labor and overhead
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Costing by Last, Standard or Average
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| Laboratory |
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The
Laboratory module brings the speed, power, and reliability
of computerized formulation to your chemists and
technicians. It reduces man-hours spent on tedious,
error-prone manual calculations and delivers a wealth
of useful information quickly and accurately. The
module is flexible enough to meet your specific
needs, no matter what types of products you manufacture.
Raw material specifications and formula physical
properties are user-definable, so BatchMaster can
perform calculations exactly the way you are accustomed
to using them. |
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Develop new formulas with new physical properties
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Assess new formulas impacts on production
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Modify formulas for multiple uses
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Assign different units of measure
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Examine lead times
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Assess markup factors
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Assign loss factors and constants
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Size formulas
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Assign costs
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Make physical property comparisons
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Update intermediate properties
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Conduct physical property searches for "global"
replacement
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Distinguish between critical characteristics
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Output reports on formula materials and physical
properties
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| Inventory
Management |
| One of
your highest priorities is managing your inventory effectively.
Process manufacturers must accurately characterize all
items they carry in inventory, keep track of their locations,
maintain appropriate stock levels for all critical items,
and be able to immediately supplement depleted stocks
if a sales opportunity warrants. BatchMaster provides
the controls and confidence necessary to reduce material
inventory. Inventories can be valued using standard, average,
LIFO, FIFO, or lot cost. |
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Define inventory by item type, price group
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Define inventory by using multiple units of
measure
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Define inventory by location, cost, lot or
serial tracking
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Manage inventory by order method, which includes:
MRP, MPS, or Re-Order Point
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Define the physical properties of any raw material
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Define QC parameters and methodology for any
Inventory Items received
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Establish list of items which can be substituted
for unavailable inventory items
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Perform inventory warehouse transfers and moves
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Perform physical count by taking full inventory
or by cycle counting
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Generate key inventory reports such as Inventory
Valuation, Analysis and Transaction Activity
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| Materials
Planning |
| Master
Production Scheduling (MPS) and Materials Requirements
Planning (MRP) offer calendar creation, flexible demand
ranges for forecasting, batch allocation, grouping of
orders for processing together, and more. MPS enables
strategic long-term planning to support projected sales.
BatchMaster automates the placing of purchase and production
orders, so that an item planned in January can have its
raw materials purchased in May and not enter production
until June. |
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Provide more accurate capacity planning or
time required as the production of a higher level
item is adjusted
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Use generic products and planning models to
forecast and plan capacity at either product family
or product level
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User-defined planning buckets allow you to
establish up to short, medium and long range planning
horizons in days, weeks, months, years or any
combination
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Packaging requirements and production job outputs
are pegged to each order promise to allow
instant visibility of customer specific requirements
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Determine "what-if" scenarios to
compare actual demand to existing plans and make
adjustments
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Evaluate and compare an unlimited number of
alternative schedule versions and identify shortfalls
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Assess the impact of producing products using
different specifications, plants or even process
lines
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| Compliance
Reporting |
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your company's reputation and the extent of its liability
are dictated by your products' compliance with specifications.
You want to satisfy your consumers' expectations without
doing them any harm. The MSDS/Compliance module has powerful
features that will automatically generate Material Safety
Data Sheets in full compliance with the OSHA Hazard Communication
Standard, SARA Title III, ANSI, and virtually all similar
government reporting requirements. This module is designed
to accommodate any required changes to meet new regulations
immediately, without the need for a program update. The
output MSDS is created as a Microsoft Word document. |
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New MSDS and labels automatically generated
upon formula change
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Customizable MSDS templates with boilerplate
for labels
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MSDS generation according to customer requirements,
formula, finished good or raw materials
type
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"SARA" (Superfund Amendment and Reauthorization
Act) processing for year-end or other
defined periods
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Reports on Boilerplate groups, Material Safety
Information, Customer History and more
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Evaluate and compare an unlimited number of
alternative schedule versions and identify shortfalls
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HACCP & FDA Bio Terrorism Act Compliance
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| Sales
Order Entry |
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Order Entry module provides tremendous versatility,
control, and power over sales and order entry policies.
Individual pricing strategies are clearly defined
for each customer based on data from your own records.
BatchMaster Sales Order Entry allows you to enter
sales orders as you take them. Sales orders can
be entered adhoc or by using a sales template that
was previously associated to the customer. Background
information about the material, customer or previous
transactions is easily obtained through the click
of a button. |
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can be entered using any defined weight or volume
for the material. Printed forms such as the sales
order acknowledgment or the invoice can have customer
item names for the items. |
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Capabilities -- Time Production Status
for accurate estimates of production capabilities,
Formula Production Status
to produce a given item, Inventory
Commitment status reports
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Customer Specifics -- Customer Order
History for a given item, unlimited Ship-To
Addresses for every Customer,
default Tax Rates, Revenue records by Customer
or Inventory Item, Sales
Contracts already in place by Cost or Quantity
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Pricing -- Orders may be entered in one
unit of measure but priced in another, access
to dynamic Pricing Matrices
including structures for Quantity,
Dollar and Percentage Discounts
by Customer by Item, by Customer by Price
Group and by Customer Class by Price
Group, Promotional Pricing and Rebates
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Order Tracking -- Order Acknowledgement,
Bills of Lading for Sales Orders and Warehouse
Transfers, Packing Slips for Shipments,
Pick Tickets and Bills of Lading
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Order Management -- Pick Lists for warehouse
personnel, Alternate Items which can be
specified when the original item
is not available
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Order Administration -- Sales Requisitions,
Quotations and Invoices
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| Production |
| The
BatchMaster Production module was designed specifically
to enhance operating efficiency of process manufacturers.
Its powerful yet flexible features expedite scheduling,
simplify batch sizing, and generate real-time information
faster and easier than ever before. Being specially
designed for the process manufacturing industry,
BatchMaster Production leaves no gaps between the
software and actual operations. BatchMaster Production's
Batch creation screen creates batches generating
one or more final products. The batch can be assigned
to a specific work center and scheduled for the
date and time it is expected to run. BatchMaster
supports advanced batch models such as SuperBatch™
and Runs. SuperBatch allows for
multiple steps of a single batch to be contained
in a single SuperBatch object. Runs
allows for large all day batches to be separated
into individual executable pieces. |
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Control the status and use of raw materials
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Initiate full or partial closing of batch
tickets, manage complex breakout batches
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Rapidly navigate between batch entry
(creation), batch ticket (adjustment) and
batch close
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Maintain centralized batch information,
starting and due dates, locations, customer
information, sales order
and batch properties
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Use Item Location to view status and
availability of Raw Materials
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Close Batch for partials for urgent shipments
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Batch Sizing Wizard to support batch
sizing by weight, volume, physical property,
available materials, quantity
of specified material(s), inventory breakouts
or anticipated yields
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Ability to initiate full or partial closing
of batch tickets, manage complex breakout
batches
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Maintenance of centralized batch information,
starting and due dates, locations, customer
information, sales order and
batch properties
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Flexibility in inventory handling to
allocate materials according to what's available,
even
if already committed
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Item Location function to view status
and availability of inventory items
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SuperBatch™ creates a batch and
its intermediates (which are themselves
"batches") in
a single operation, with
top-down management of sub-batches
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BOM Substitution at Batch Close for different
size containers and BOM Sizing options to
match to shipping obligations
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A number of management reports including:
Critical Materials to flag shortages,
Expiration Date to assure
materials are viable and Material-Where-Used
to show where specific
materials are used in all formulas
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| Purchasing |
| BatchMaster
Purchasing functionality provides sophisticated
management and organization to your purchasing
operations. Purchase order processing simplifies
item and vendor selection, reducing costly
errors and increasing productivity while providing
management with information required in making
intelligent decisions. The entire purchasing
process is supported, from securing quotations
to placing orders to receiving and issuing
vouchers for incoming materials. |
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interfaces seamlessly with accounting partner
software, automatically posting inputs to
Accounts Receivable, Accounts Payable, and
General Ledger. |
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Access to real-time status of production
history, contract history, discounts, alternate
items and tax information
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Ability to create purchase requisitions
for any critical materials required by a
production batch
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Ability to enter Purchase Orders in one
unit of measure while providing pricing
in another unit of measure
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Ability to automatically generate Purchase
Orders by Re-Order Point ("ROP"),
Economic Order Quantity
("EOQ"), Material Requirements
Planning ("MRP") or Master Production
Scheduling ("MPS")
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Support for purchase on demand for make-to-order
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Access to Purchase Contracts and Vendor
Price Concessions
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Access to full tracking to assess Vendor
Performance
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Ability to generate reports on critical
materials, expected delivery and open Purchase
Orders
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| Quality
Control |
| BatchMaster's
Quality Control facilities are versatile and offer
support for every phase of your operations, from
receipt and acceptance of raw materials, through
production of intermediates, to inspections of finished
goods before shipment to customers. QC can be provided
for materials at purchase receipt, production or
sales shipment. Consistent quality is what your
customers expect. |
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QC characteristics definition and desired
test results with test creation
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Specify target values, control limits
and maximum allowable defects
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Separate QC options for Sales (outgoing)
and Purchasing (incoming)
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Order/Post Inventory testing
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Inspection without tracking (sampling)
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Critical reports for Formula Test, Production
output, down to Item Test
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| Bill
of Materials |
| A large
amount of work that needs to be done in Process
Manufacturing is combining, mixing and preparing
(e.g., heating, pressurizing) combinations
of raw materials and intermediates. Towards
the end of the production process is the "packaging"
of your production output, into forms of use
for customers, and often in a manner to accommodate
Sales with promotional packaging. You need
a great deal of versatility at this BOM stage,
especially with consumer products, where in
which packaging provides the "sizzle."
Also, when providing materials to customers
that they then remanufacture, your containers
must be effective yet low in cost. |
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Containers of all varieties, bottles,
caps and labels to boxes and buckets and
lids to cartons and pallets
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Create a BOM defined in terms of component
items
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Mix formulas into a BOM, assembling or
filling a container with the finished good
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Define the BOM in terms of overhead cost,
fill level, measurement method, assembly
method
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Explode a BOM from a Finished Good backwards
in a tree structure with filters to define
any number of levels
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| Capacity
Planning |
| Available
Capacity is the most fundamental basis for decision
making for your company. Successful companies carefully
manage their capacity and make effective scheduling
decisions. BatchMaster Enterprise Master Production
Scheduling ("MPS") provides rough-cut
capacity planning, allowing you to compare projected
resource requirements to available resources and
process constraints. You can examine all critical
resource groups, including equipment, storage and
labor and compare alternative scheduling scenarios.
Rough-cut capacity planning considers resource calendars,
projected production line throughput rates and planned
downtime to compare planned usage against projected
available capacity. You will quickly spot idle capacity
along with process bottlenecks to guide you in better
balancing your resource utilization. |
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Capacity constraints can be assigned
at machine, group, department or plant level
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You can smooth schedule and override
adjustments
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You can view effects on utilization of
such as labor, equipment or storage
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You can optimize the resource plan and
spawn a series of production jobs to load
your facilities
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Process Cell Module provides snapshots
of commitments against a time line
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You can adjust schedules for each process
cell for a given batch ticket to schedule
multiple batches
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