Mechanical industry
Mechanical Industry
In the automation of the mechanical industry, challenges related to production process control arise. The functional capabilities of the UNA.md platform allow for cost calculations, calendar and resource planning, management of work execution schedules, loading and utilization of production resources, etc. Simultaneously, comprehensive management of territorially distributed production units within a holding or corporation is possible. The platform supports both mass production and large batch production planning.
UNA.md supports a multi-level product structure (material – part – subassembly – assembly – … – product). The management of normative and reference data involves the use of basic classifiers (glossaries) for products, materials, parts/subassemblies, purchased components, and equipment consumption standards. During technical preparation and production design, material specifications (composition of products and subassemblies), technological sheets, etc., are developed. Operational sheets with material/component consumption standards, as well as labor consumption standards, are also developed.
During the production process, based on the production plan, limit and requisition sheets are prepared, reflecting the quantity of consumable materials available at the unit and required for production activities. Using the internal transfer mechanism between warehouses and production units, orders for necessary materials are placed, and surpluses are moved to storage. Comprehensive documentation allows for the reflection of both the normative quantity and excess of materials used in the production of each product type, as well as consideration of specification deviations in materials (recorded in the consumable material replacement document).
Following registration in the system, production cost calculation is carried out based on accumulated information: production reports, material movement documents, and the formation of accounting entries. Production cost calculation can conventionally be divided into normative cost calculation and actual cost of the product unit, taking into account direct and indirect costs. By establishing a production schedule, the planned cost can be obtained, considering the product type, individual units, or the entire production plan. Due to the gradual reflection of production process information, the actual cost is formed, accounting for the real cost of consumable materials, specification deviations resulting from replacements or production percentage changes, and the quantity of defective products.
In implementing the program in mechanical industry enterprises, the main focus is on automating the entire production cycle – technical production preparation, sales and production planning, supply planning, and production cost calculation. Integration with quality management systems such as ISO is possible.
With complete production automation, the real possibility of automatically and promptly calculating the production schedule arises, as well as determining the completion percentage of an order (lot), obtaining detailed information about each part (at what manufacturing stage it is in), and receiving information about workers who produced a specific part. Daily recording of contracts within production management allows for production volume forecasting and comparison of actual and required production capacities. The system allows integration with control equipment such as electronic scales, sensors for production stages, and resource sensors.
A developed personnel record system enables the organization of attendance record and control system at the workplace using low-cost chip technology. This improves discipline in production, which ultimately positively impacts the quality of finished products.
This solution is part of an integrated enterprise information system based on the UNA.md platform, offering the following functionalities to manufacturers in the mechanical industry:
Production Preparation Technology
Managing the database of design and technological specifications, taking temporal changes into account, including:
- Sequence of technological operations
- Time standards for performing operations
- Labor standards per operation
- Material and semifinished product consumption norms
- Indirect cost standards
- Formation of the product structure (node, part) in a tree-like form.
Sales, Production, and Supply Planning
- Recording consumer product orders (lots)
- Creating sales orders for production, developing the plan for finished product production
- Calculating the production schedule for workshops and sections
- Developing production orders for workshops and orders for custom production
- Assessing the availability of materials and components for production orders
- Creating a supply plan for workshops and sections
- Planning material and component stocks
- Calculating the procurement needs for materials and parts, developing the procurement plan
Production Management
- Maintaining a database of primary accounting documents:
- Transfer notes for materials introduced into production
- Transfer notes for products delivered to warehouses
- Maintaining a database of manufacturing operation sheets for parts and assemblies:
- Sequence of technological operations
- Time standards for executing operations
- Labor standards per operation
- Material and semifinished product consumption norms
- Indirect cost standards
- Automated control of actual production against the plan
- Material depreciation records
- Transfer notes for transferring semifinished products (parts, assemblies) for finishing to subcontractors
- Receipt records for services, work
- Notifications regarding material substitutions
- Managing the status of unfinished production
- Compilation of workshop production reports for the respective period
- Automatic generation of accounting entries based on accounting documents.
Calculation of production cost
- Preliminary assessment of production costs for consumer product orders
- Calculation of planned and actual production expenses by departments, cost categories, and economic elements
- Calculation of planned and actual cost calculations, analysis of deviations
- Calculation of production costs for parts and assemblies at all production stages
- Calculation of production cost for unfinished inventory
Reports section:
- Operational production reports
- Daily production schedule
- Daily production achievements (quantity)
- Overall performance (human resources)
- Daily productivity (workers)
- Daily production achievements (lots)
- Collaboration overload
- Costs of labor and time per lots
- Lot-based realization process
- PLAN (STANDARDS)
- Lot-based material budget (GSP)
- Lot-based wages budget (operations, lots, GSP)
- Production tree hierarchy
- Time resource budget
- Product cost calculation (synthesis)
- Synthetic material resource budget
- Calculation of required material quantities according to the production plan
- Production plan
- TMC (Time-Motion-Cost)
- Warehouse balances and turnovers
- Detailed turnovers by documents
- Materials and fixed assets issuance
- FINISHED PRODUCT
- Warehouse entries (daily)
- Warehouse exits (daily)
- Storage and turnovers by warehouses (quantity)
- Cost – Stocks and turnovers
- PRODUCTION (Expenses)
- Operational report on production plan fulfillment
- P-35 Synthetic material accounting
- Calculation of manufactured product production cost
EPAM Systems 13 from Unisim-Soft invites you to become acquainted with the comparison between EPAM ERPSAP and RDS technology with the UNA.md platform, and the implementation using a similar RDS methodology by Coninfo OOO company.
Presentation from Unisim-Soft