Products - NGR Technosys

NGRERP's machine maintenance software functionality provides the ability to track machine maintenance intervals and be notified when a given machine requires maintenance. Maintenance management allows for the establishment of machine component lists and associated mean-time between failure (MTBF) standards, creation of standardized procedure lists, and the association of procedures and maintenance documents to specific machines and processes. NGRERP's production scheduling and maintenance management functionality are fully integrated, thus allowing for time to be reserved on the production schedule for preventative maintenance activities. In addition, plant floor personnel can immediately initiate machine maintenance in the event of machine anomalies and downtime. 

Machine Maintenance Highlights

• Supports preventive or scheduled maintenance and non-planned or on-demand maintenance request
• Downtime resulting from scheduled equipment maintenance activities is included in production scheduling activities
• System notifications of preventive maintenance orders which require machine downtime
• Supports entry of a machine BOM or equipment part list and on-line maintenance instructions
• Supports creation of maintenance work orders and scheduling of associated maintenance labor requirements
• Plans purchases of MRO items, which are managed in inventory and consumed by maintenance activities

Good Manufacturing Practices (GMP) refers to an organization’s ability to ensure that products are consistently produced and controlled to appropriate quality standards in the production of foods, pharmaceutical products, and medical devices. GMP covers all aspects of the manufacturing process, product storage and transport, serial number tracking, and lot traceability. 

NGRERP supports GMP through audit controls of transactions, electronic signatures, and version control with engineering change management of formulas and bills of materials. NGRERP also enables forward and backward lot traceability, shelf life management, and tracking and control of dangerous and restricted items. The overriding principles of GMP include designing quality into a product and controlling all aspects of the production process and associated material flow.

NGRERP's production reporting and shop floor control functionality offers discrete and process manufacturers the ability to record real-time labor and production data. Production reporting can be performed by employees in a variety of manners, including data entry with keyboards and touch-screen devices and scanning from tether-attached, handheld, and forklift-mounted devices. NGRERP's production reporting and shop floor control capabilities enable efficient data entry and organization-wide access to production data, supporting inventory management, customer service, financial management, and costing processes. 

Production Reporting Highlights

• Supports capture of materials, packaging, and labor consumed and finished goods produced by routing process step
• Manufacturing variances can be recorded and analyzed
• Supports separate data capture of finished goods production and inventory putaway
• Supports one-step production reporting for organizations that prefer more simplistic recording of finished goods with simultaneous backflush at standard of materials and labor consumed
• Supports recording of machine downtime and production scrap for accurate costing and root cause analysis
• Supports tracking of employee exposure to hazardous chemicals
• Supports lot tracking from ingredients through intermediates to finish goods
• Supports serial number tracking from components through subassemblies to finished goods
• Supports reporting of disassembled manufactured goods, kits, and assemblies
• Supports production recording in multiple units of measure
• Supports catch weight processing

NGRERP software supports kitting and assembly processes for manufacturing and distribution organizations. Kitting can be performed through a picking process or as a manufacturing process where associated labor and burden are also collected for accurate costing purposes. 

In NGRERP, kitting and assembly processes use the establishment of an infinite-level bill of materials. Manufactured kits and assemblies also use associated routings. In the NGRERP system, organizations can establish the schedule for manufactured kits and assemblies through the production planning or MRP process. 

Assembly processes can either be performed within the given organization or as outside operations by a third-party company. If the assembly process is outsourced to a third party, NGRERP can generate a purchase order for the assembly services performed and shipping documents for sending the raw materials and components to be consumed to the third-party assembler. 

Kitting and Assembly Highlights

• Supports multi-level bill of materials
• Kitting can be performed through a picking process or as a manufacturing process where associated labor and burden are also collected for accurate costing purposes
• Supports multi-step routings for manufactured kits and assemblies
• Allows item substitutions within a kit
• Supports serial number tracking when applicable to kitted and assembled items
• Tracks associated cost to manufactured kits and assemblies
• Supports the ability to disassemble kits and assemblies for consumption of component items in other processes

NGRERP's manufacturing software functionality includes complete engineering change order (ECO) processing for discrete and process manufacturers. Through the ECO process, a new version or revision of a given product’s bill of materials (BOM) or formula can be created. In NGRERP, the given engineering change can be routed through the organization for online review and approval for the promotion of a proposed BOM or formula to an active status. The new version of the BOM or formula would be used in material requirements planning (MRP), production scheduling, production recording, and for updated product costing. A similar engineering change process is used for the revision of production routings. 

Engineering Change Orders Highlights

• Supports creation and routing of engineering change orders (ECO) through the organization for review and approval including on-line electronic signatures
• Maintains version and revision control in product development and manufacturing
• Used for bills of material (BOM) for discrete manufacturing, formulas for process manufacturing, and associated product routings
• Supports infinite notes to be associated with a given ECO
• Supports MRP planning based on applicable ECO effectivity dates on BOM’s, formulas, and routings

In conjunction with bills of materials for discrete manufacturers and formulas and recipes for process manufacturers, NGRERP's manufacturing software functionality uses routings to help manage the entire production process. Routings consist of a series of steps which define the sequenced processes and work centers a given product must go through for its production. 

NGRERP's material requirements planning (MRP) and production scheduling processes generate work orders and batch runs based on a product’s routings. Individual routing steps define anticipated process standards, and can either be established as the amount of time to produce a given quantity of product, or as the quantity of product which can be produced per unit of time. Routings also include defined standard setup and queue times by process step. 

In NGRERP, a product can have an infinite number of active routings defined at either the organization or facility level, with a specified rank ordering of routings. In the MRP process, NGRERP uses product routines and other associated data to systemically create tentative production schedules by facility to best meet anticipated customer demand. 

Routing Maintenance Highlights

• Routings support revision levels, version tracking, and effectivity dates
• Supports routing run time by operation step entered as either units per time or time per unit
• Supports standard setup and queue times by routing operation step
• Support by-products and co-products
• Supports the entry of raw materials, components, or ingredients consumed per routing step or operation
• Supports unlimited work instructions and notes by routing and individual step
• Supports subcontracted and outside third-party processing within routings
• Supports entry of labor required per routing step
• Multi-level where-used functionality enables rapid access and mass change processing
• Supports entry of inspection and packaging processes as operational steps within routings

NGRERP's process manufacturing software functionality supports the management of scalable batches. Companies can establish formulas and recipes with associated routings for batch production at defined standard batch sizes. Assuming a process manufacturer’s operations require variable batch size production, NGRERP can scale the associated ingredients and intermediates in the formula to support the desired scalable batch size.

NGRERP's process manufacturing software functionality supports complete formula and recipe management. Multi-level formulas can include ingredients, intermediates, and other formulas. Through the engineering change processes in NGRERP, formulas can go through version revisions. NGRERP's where-used functionality provides complete visibility to specific ingredients, intermediates, and formulas which are used in the production of multiple products. Through the integration of formulas and associated processing instructions and notes, process manufacturers can create recipes which are used during batch process production. 

Formula and Recipe Highlights

• Supports infinite-level formulas with yielding at the top level or ingredient level and rank-ordered ingredient substitutes
• Products can have global formulas or unique facility-specific formulas
• Supports scalable batches
• Supports recipes through the integration of formulas and associated processing instructions and notes for use during batch process production
• System maintained version and revision control with a fully-integrated engineering change order process
• Formulas support nested formulas and intermediates and can have infinite notes and instructions
• Supports online review of formulas via single-level and multi-level explosion
• Multi-level where-used functionality enables rapid access and mass change to all finished goods using specific ingredients, intermediates, and nested formulas
• Formulas and recipes are easily duplicated and updated for the same product or a new product
• Formulas are pulled into work orders or batches for tracking and recording of actual ingredients consumed or backflushed at defined standards
• Supports co-products and by-products
• Supports lot control tracking, shelf life management, product grading, and hazardous materials tracking and reporting

At the heart of product definition for produced items in the NGRERP system are bills of material (BOM's). BOM's are primarily used for discrete manufacturing, assembly, and kitting processes in NGRERP. BOM's can have infinite levels and include pseudos, sub-assemblies, and phantoms. Through the engineering change processes in NGRERP, BOM's can go through version revisions. NGRERP includes where-used functionality for visibility to where specific components and sub-assemblies are used across all products, enabling rapid mass change processing. 

Bill of Materials Highlights

• Supports infinite-level bills of material (BOM)
• System maintained version and revision control with a fully-integrated engineering change order process
• BOM’s support pseudos, subassemblies, and phantoms and can have an infinite number of lines of notes
• Supports online review of BOM’s via single-level and multi-level explosion
• Multi-level where-used functionality enables rapid access and mass change to all BOM's using a specific component material or subassembly
• BOM’s are easily duplicated and updated for the same product or a new product
• BOM’s are pulled into work orders for tracking and recording of actual components and subassemblies consumed or backflushed at standard
• BOM’s support yielding at the top level or component level and rank-ordered component substitutes