PPS One for SAP Business One

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PPS One - Manufacturing Add-On for SAP Business One

Using the technology of SAP Business One, CP CIM-POOL AG integrates PPS One to provide a comprehensive business solution software for small and mid-sized manufacturing companies.  For strong manufacturing capability along with fast, cost effective implementation you can't do better than PPS One. 

We work with executives that are serious about bringing advanced manufacturing functionality to their SAP Business One software.

Fully integrating all business processes will make your manufacturing company more transparent, more controllable and more profitable. You'll be more secure and confident of your delivery times, improving customer satisfaction.  Your order margins will become more predictable and reliable.  And you'll achieve higher utilization of labor and machines, with fewer indirect hours.

Flexibility in production -- PPS One supports a wide range of manufacturing methods:

PPS One in conjunction with SAP Business One offers all the modules that a manufacturing company needs:

  • Purchasing
  • Materials management
  • Material requirements planning (MRP)
  • Capacity planning
  • Engineering/Design
  • Job preparation
  • Production
  • Assembly
  • Costing
  • Sales
  • Customer service
  • Customer relationship management (CRM)
  • Human resources management
  • Finance
  • Banking

How to Tell if You're a Good Fit for PPS One

  • Companies who produce products on basis of customer orders, demand forecasts, minimum stock quantity, service levels
  • Number of production orders: 500 — 20,000 per year
  • Lead time of a production order: 1 hour — 2 years
  • Frequent changes to production orders: material, production processes and due dates => planning & scheduling changes
  • Presence of a dedicated production manager / planner in the company
  • Lack of integrated information exchange and presentation between all departments of a company
  • Require integrated capacity planning & scheduling versus finite capacity growing and changing part lists
  • Required to provide accurate and reliable customer delivery dates / confirmations to avoid penalties
  • Deliver short termed customer orders

PPS One Functionality for SAP Business One

PPS One Master Data Management

Since complete master data information that meets the needs of small and mid-sized manufacturers is indispensable for the successful, optimized use of PPS One, all necessary master data is structured in a logical (i.e. practice-specific) fashion. This allows the data to be entered and maintained efficiently.

Work centers

The system is able to clearly define work centers.  Generally, it differentiates between four different types of work centers:

For every work center, the number of work centers, the corresponding supplier address and (optionally) an image (machine) are recorded.

Time factors:  All key basic data for the determination of available capacity is recorded for every work center.

Cost rates:  Full and marginal cost rates to be used as a basis for costing evaluation can be provided for a work center.

Memos:  Any and all information, notes and reports from revisions, repair reports and even downtime can be entered.

Work center calendar:  An operational calendar can be assigned to the selected work center.

User-defined fields:  Additional user-defined fields can be created and displayed for customer-specific work center information.

Work center groups:  Work centers may be added to listed work center groups. This assignment can be used as a basis for all planning and costing evaluations.

Machine group

When scheduling/dispatching an operation to which a machine group has been assigned, the operation is scheduled for all work centers assigned to the machine group, and lead times are calculated. The work center with the shortest lead time will subsequently be saved with the corresponding operation.

Multi-machine operation

The complex requirements of multi-machine operation can be met easily and efficiently by assigning different internal work centers to a single planned work center.

The setup and run times (target times) of an operation within the manufacturing process are dispatched and scheduled following verification of available capacity, required internal work centers and in  combination with the assigned planned work center.

Operating calendar.  Operating calendars can be automatically generated for several years in advance. Leap years are taken into account. Saturday and Sunday are defined as non-working days (default values), so that only general holidays need to be entered.

Work center calendar.  A specific operating calendar is assigned to every work center. Specific differentiators such as level of use, revisions, etc. for any given work center can be defined down to the day. Opening and/or assigning multiple calendar years allows production orders to be scheduled over the course of several years.

Work schedule models.  Various work schedules can be precisely defined using the available daily capacity, taking into account the beginning and end of the working day as well as breaks. This not only displays the expected completion date when scheduling production orders, but also the exact time of shipping and delivery.

Weekly schedule.  All work operations yet to be completed by the selected work center can be directly viewed for any selected time frame. The corresponding link button (orange arrow) provides direct access to production orders and/or operations.

Work center calendar: Daily information.  The work center calendar displays all factors that influence daily capacity for the selected day and work center as well as the actual or simulated hourly workload triggered by manufacturing orders.

Work center calendar: Updating.  Updating allows available capacity information to be adapted to the current operating situation easily and efficiently.

Planning horizon.  An unlimited number of calendar years can be set up, allowing complex orders and projects that often extend over the course of several years to be scheduled.

PPS One Routing and BOM management

Items to be manufactured are assigned an operation plan that defines the materials (BOM - bill of materials) and work processes required for production. This plan is the key to success since it forms the basis for costing evaluations, the manufacturing process and logistics – and that’s where the power of PPS One can help you achieve success.

Operation Plan.  Any given number of different and/or alternate operation plans (versions) can be entered. This allows for maximum flexibility in BOM design and the selection of manufacturing processes.

Additional information

The operation plan header can list additional information depending on the requirements at hand:

The calculated manufacturing costs per unit determined during pre-costing can also be transferred directly into SAP Business One as needed. The link button provides direct access to the master customer data for the selected customer.

Operation plan status.  This area allows the user to determine whether a neutral operation plan for production is released or locked.

User-defined fields.  Additional user-defined fields can be created and displayed for customer-specific information.

Memos/Documents.  Memos allow the user to add further information, notes, clarifications etc. regarding the work plan to be created. In addition, all relevant documents (e.g. inspection instructions) can be assigned for the item to be produced.

Material items.  You can use various criteria to search for items to be listed as material/BOM items and incorporate them into the operation plan. The link button provides direct access to master item data and the corresponding item. Information regarding amounts, allocation base, memos, documents (e.g. for QA reports) and other data can also be added to material/BOM items. For pre-costing purposes, a price per unit can be assigned specifically to material items.

Assigning material/BOM items to operations.  One or more material/BOM items can be assigned to an operation. This optimizes the requirement date for material procurement (planning).

Operation items

Depending on the requirements, different information can be assigned to operations to define an activity or work process.

Copying operation plans.  This function makes setting up additional operation plans easy, efficient and straightforward. It is possible to copy, as an example, only the BOM from one operation plan and only the work processes from another, into a new product.

Use of structural components.  The structural components utilization history allows the user to display which assembly contains the item, and what the higher-level assemblies are, all the way to output of the final/finished product.

Structural pre-costing.  Product costing can be carried out across all BOM levels (costed multilevel BOM) and issued in a manner that separates all material and manufacturing costs. Correspondingly, to calculate the material costs of a complex system, only the prices for purchased items (standard items and raw materials) need to be available; to calculate manufacturing costs, only the setup (TR) and run times (TE) of the necessary work processes need to be known.

Operation plan recalculation.  Following increases in material prices or changes to work center cost rates, it is possible to recalculate all operation plans and enter the calculated cost of production as part of the master data.

Costed multilevel BOM.  The structural display immediately shows the composition of a product across all levels.

Parts usage / Component exchange.  The parts usage component displays all BOMs in which the selected item is listed. The component exchange feature allows you to replace one item with another. Optionally, this can be done across all levels.

Preliminary lot size costing.  A product routing can be calculated for five lot sizes simultaneously and printed out together with the relevant information (e.g. price of materials, internal and external assembly costs, production costs, cost of goods sold, sales price).

PPS One Production Order Management

Extreme user-friendliness and comprehensive direct access to all necessary information and data ensure efficiency in day-to-day operations.

Production orders.  You can search for and display all production orders according to various criteria. This allows the user to directly select, reschedule and edit an ongoing production order or query its details.

Entering and copying production orders.  Existing production orders can be selected and copied in order to enter new production orders. Where needed, the actual values of an existing production order can be used as target values of the production order to be created.

Scheduling

The following options and others are available for scheduling or entering a production order:

Dispatching / Graphical control Station.  An overview graphic with relevant information is available for verifying and displaying the lead time of a production order and its individual work processes at specific work centers. The link button (orange arrow) gives direct access to detailed information about the corresponding work process or the weekly schedule of the selected work center.

Material shortage display.  The detailed listing of availability for all BOM and material items down to the most basic step (costed multilevel BOM) can be issued. Additional limiting options allow you to display the desired figures precisely.

MRP/BOM items/  Where necessary, missing parts, target amount and date required etc. can be altered for every individual material/BOM item.

MRP overview.  The warehouse and MRP (material resource planning) figures are immediately available through direct access to the selected material item for the product. The SAP Business One item master allows the user to choose the MRP overview for the selected item. All relevant scheduling figures are listed concisely and by date. Users can directly access the corresponding customer, purchase and manufacturing orders from every MRP line by clicking the link button.

Purchase order from material shortage.  Purchase orders for parts such as standard parts and raw materials can be created directly in the system. The connection between the manufacturing order and material items with created purchase orders will be directly displayed in the material shortage display. The link button grants direct access to the order.

Work processes for external production (extended workbench).  Orders for work processes carried out at a supplier's site can be created directly within the system. The link button provides direct access to the corresponding order from the production order.

Creating a production order based on material shortage.  From the material shortage display, sub-manufacturing jobs can be generated and/or scheduled directly for items manufactured inhouse.

Customer order-based production orders.  Production orders for items manufactured inhouse can be generated directly from the customer order. All relevant information (amount, customer order number, customer etc.) are automatically entered into the production order.

MRP-based production orders.  Within the MRP (material resource planning) component, production orders can be generated directly from the order recommendation report.

Issuing shop papers.  A wide selection of options is available for issuing different types of shop papers.

Flexible manufacturing based on production order.  Material/BOM items and work processes can be added to or edited in created or existing production orders. In addition, production amounts that differ from the production order amount can be entered in the individual work processes (work process splitting). Changed production orders can be rescheduled repeatedly.

Sequence planning.  Multiple production orders can be selected and re-scheduled simultaneously. In ongoing, already started production orders, dates and production quantity can be changed at any time. The order in which the selected production orders must be processed can be freely determined. Unless dispatching has been completed with the "Dispatch all” function, all rescheduled production orders can be returned to their original status at any time.  Simultaneous changing and rescheduling of multiple production orders.

The planning process is supported by various visualization graphics:

Confirmation of material/BOM items, work processes.  Planned as well as unplanned acquisitions of materials can be entered into the production order without switching applications. Working hours can be confirmed manually or via an interface with a wide range of production data acquisition (PDA) systems.

Production order confirmation.  All salable finished products can be booked directly into the warehouse via full or partial delivery. In addition, various selection criteria are available for individual postings.

Costing information.  Continuous or rolling product costing analysis can be viewed at any time for the selected production order. Online tracking is carried out with every confirmation message posting.

Graphical support.  If dates or production amounts are changed while planning/scheduling a production order, the effects on the process can be displayed in comparison to the original/current status.

Confirmations.  All material deliveries per BOM/material item and all confirmations (detailed times) per work process are stored in detail with every corresponding production order and can be accessed at any time.

Shop papers.  Shop papers can be freely configured using the Report Generator supported within PPS One and customized to company specifications.

PPS One Analyses

Every manufacturing company is different, and their requirements for analyses and reports are just as unique. Corresponding selection options and freely definable analyses (Report Generator) make it possible to extract custom reports from an overwhelming amount of available data. One-click access to key figures and performance indexes is available at any time.

Weekly schedule for work centers.  The weekly schedule or control station shows the operations started/not yet completed for one or more work centers for a specific period of time according to preset selection criteria. Users can also determine whether only operations of actual production orders and/or simulated ones as well are to be displayed.

Workload overview.  The workload of the work centers is displayed in a clear, easy-to-understand graph. It can also be created in absolute values – as a condensed table-form display over four time periods of the user's choosing.

Backlogged production items.  All backlogged operations can be displayed according to various selection criteria. The backlog duration of specific processes/operations is given in days.

The product costing analysis.  The very extensive selection options help users meet the most diverse and if necessary even extremely strict requirements for cost accounting evaluations. A few examples:

 

The "work in progress (WIP)" label.  Within selected options such as project, production order and item/product line.  All evaluations labeled as work in progress are listed separately according to material and production costs. Partial manufacturing order deliveries are taken into account during the evaluation and are explicitly displayed as such. The "work in progress (WIP)" label is available at any time and on any freely chosen date for specific points in time.

Company-specific evaluations.  The Report Generator allows evaluation results to be used or processed further almost without restriction and in line with customer-specific requirements. A few examples:

Workload overview.  The simultaneous display of four time periods of your choosing gives you the maximum possible overview of the capacity utilization of individual work centers (machines etc.).

Workload graph.  This clearly structured, easy-to-comprehend graph makes it easier to evaluate the company's overall operational workload.

Weekly schedule/Control station.  All operations still to be completed are displayed for the corresponding work centers over a selected time period.

Product costing analysis.  The progressive and/or continuous product costing analysis shows the results of one or more specific production orders, projects etc.

More Information - Brochures, Video and Your Next Steps

Aether Consulting will be happy to show you how SAP Business One + PPS One, the integrated, modern, end-to-end solution for small and midsized manufacturing companies, can meet the unique requirements of your business.

Download a PPS One PDF brochure.

View the PPSOne demo video.

Contact Aether Consulting for PPSOne for SAP Business One

Aether Consulting is a North American Partner for PPS One.  Contact us at sales@aetherconsulting.com.