Manufacturing management

We help our customers to build a manufacturing system for all discrete manufacturing types ETO, MTO, MTS and repetitive, that ensure agility, flexibility, and integrated product life cycle management.  

Usually customer-focused manufacturing companies use several types of production, including MTS. IPL Consulting solutions allow to combine various scenarios of production management/ planning and customize the system to the specific enterprise needs.

Project production management (PPM) (Engineer-To-Order)

• Building a holistic end-to-end project and production process management system
• Operational management of design and operational documents development
• maintains project and engineering documentation integrity, monitor workflows, provide project status in real-time
• Synchronization of design processes and Engineering Document Management with production
• Management of project works with detalization by its composition (WBS). Maintaining a single end-to-end work schedule
• Management of project costs within the context of object elements
• Management of project’s resourcesand materials budgets, labor input budgets
• Planning of procurement and production in accordance with project schedules and needs of the project work
• Management of project’s inventory with borrowing/reimbursement options

Customer-focused manufacturing management (Unit Effectivity, Make-To-Order, Assembly-To-Order)

• Product configuration management
• Master data management as a basis for Industry 4.0
• product lifecycle management
• Demand forecasting and safety stocks calculations
• Analysis of the resource’s utilization and calculation of planned capacity utilization
• Calculation of the resource’s utilization and planned utilization of capacities
• Specification of critical capacities and materials
• Order acceptance: сconfigure, price and quotation
• Customer order management
• Management of assembly units’ completeness
• Quality management, built-in analysis of quality deviations impact on the result
• Service management
• End-to-end supply chain visualization — from production through shipment, service, warranty, and refurbishing

Management of multi-tier distributed companies

• Movement or transfer material or items between sites or warehouses
• Consolidation of data from sites at financial entities
• Shipment to common customers and receive from common vendors
• Share administrative functions between sites
• Centralization of payment processing (between sites having the same currency)
• Visualization Accounts Payable and/or Accounts Receivable transactions across sites
• Creation of items at one site for multiple sites
• Visualization of item availability across sites
• Creation of vendors at one site for multiple sites
• Creation of customers at one site for multiple sites
• Creation of purchase orders at one site for multiple sites, allowing for accumulation of like items to get quantity breaks from vendors
• Demand and source vendor site PO-CO processing automation

Foundry management

The solution solves main task is to prevent low-quality castings from entering the further production stream and supports strict technological control of the entire production process.

• Casting Quality management related on complete digital data of manufactured units in the foundry
• Establishing stable processes based on analytics of castings quality statistics
• MPS planning for good quality castings and casting bushes on the molding line
• MRP planning for all semi-finished products
• Reorder point planning on core section
• Incoming inspection for the main purchased materials
• Short technological routes usage, with division into semi-finished products (justified by the topology of production)
• Unique items movement tracking by assigned numbers
• Batch traceability and batch accounting of steel
• Allocation of only basic materials to the BOM

MRO management (Maintenance, Repair and Overhaul)

• Creation of a “digital product passport” for maintaining the service BOM (for a series or modification)
• End-to-end product lifecycle management:
  • Tracking of Engineering Document changes through all the product lifecycle
  • Tracking of the BOMs of product by identifying number
• Registration of the actual product structure during the initial acceptance and defect detection of the product
• Changes registration in the physical product structure in the process of replacements, installations and removal of parts, sensors, or assemblies
• Tracking the operating time and state of the product nodes and the product as a whole
• Tracking of specific product nodes through serial numbers and support of separate cost accounting (government, commercial projects, etc.)
• Annual and operational planning of repairs, of procurement and production in accordance with project schedules, current needs and retrospective data of past periods works
• Service Terms & Warranties Management
• Incident & Call Center service management
• Field Service Management
• Service and Factory Repair Management
• Repair quality management
• Complaints management
• Analytics for all levels of management:plan-fact analysis at all stage of end-to-end product repair execution
  • defective items report,
  • fault detection report,
  • report on costs and estimation of the cost of repairs in the context of products