An Enterprise Resource Planning (ERP) system with a completely new architecture, tailor-made for the requirements of the process industry. Developed with a leading plastics compounding company, there is now for the first time an ERP system that holistically supports all critical processes of this industry in an optimal way without additional modules and interface problems. By specializing in recipe-based production, Poly.ERP offers a wide range of starting points for improving production processes.
Procurement Management
MASTER DATA MAINTENANCE
- plant of input materials by types
- raw materials, intermediate products, packaging
- plant of commercial goods
- purchase price lists
- definition of product-supplier relationships
- mapping of chemical properties and hazard classes of input materials and input material groups
ORDER / GOODS RECEIPT
- ordering of input materials, packaging and merchandise
- call-off of customer supplies
- goods receipt plan
- barcode-guided goods receipt of input materials and packaging
- packed goods
- silo delivery
- goods receipt inspection and invoice verification
- interface supplier invoice to accounting
- goods receipt and order archives
QUALITY ASSURANCE
- control of quality assurance in the ordering and goods receipt process
- supplier evaluation
- raw material inspection goods receipt
- silo
- packed goods
MATERIAL PLANNING
- calculation of material requirements for input materials, packaging, intermediate products, trading goods, finished goods
- consideration of production plan, inventory, goods receipt plan
OTHER
- integrated task management
Order management
MASTER DATA MAINTENANCE
- investment of finished goods
- definition of customer product relationships
CUSTOMER ORDER / ORDER
- sales order according to different process types
- delivery order
- provision order
- contract manufacturing order
- consignment order
- internal transfer order
- sample orders
- integrated Reconciliation Production Planning
- order monitoring
- delivery processing
- barcode guided loading control
- packed goods
- silo
- goods issue plan
INVOICING
- delivery invoice, payroll invoice, pro forma invoice,
- consignment invoice, internal invoice,
- other types of invoices,
- various credit note types, cancellation invoices
- Interface outgoing invoice accounting system
- order, invoice and delivery archives
- integrated task management
- transport management
TRANSPORT MANAGEMENT
- freight zones
- freight purchase
- transport order/collection order
- bill of lading creation (CMR)
- central freight control
- integrated task management
- inventory management
INVENTORY MANAGEMENT
- container oriented stock list
- silo inventory management
- div. methods of inventory valuation
- special stock lists
- customer inventories
- minimum stock lists
ORDER / GOODS RECEIPT
- ordering of input materials, packaging and merchandise
- call-off of customer supplies
- goods receipt plan
- barcode-guided goods receipt of input materials and packaging
- packed goods
- silo delivery
- goods receipt inspection and invoice verification
- interface supplier invoice to accounting
- goods receipt and order archives
INVENTORY CHANGE LOG
- traceability of all attribute changes for each individual inventory container (goods receipt, stock movements, quality status changes, quantity changes, packaging changes, production origin, production consumption, goods issue ...)
HISTORICAL INVENTORY RECORDS
- traceability of all attribute changes from former inventory
INVENTORY
- inventory Count Lists
- barcode guided inventory
SCAN FUNCTIONS
- goods receipt
- production Packing
- raw material consumption Production
- decanting
- silo filling
- batch tracking
- outgoing goods - loading
- production plant shutdown
- storage location transfer
- production planning and control
PRODUCTION CONTROL STATION
- batch-oriented planning and control of production orders
- integrated sales order/production order planning
- deadline monitoring via traffic light system
- mapping of partial productions
- arbitrary allocation of customer orders and internal production orders to production batches
- mapping of makeready, downtime and downtimes
- planning of premixes and color batches
- planning and control of production supply
- control station history
PRODUCTION CONTROL
- working papers
- control of insertion and special insertion
- production equipment
- premix silo
- integrated task management
- feedstock availability
- batch tracking
- mapping of customer batches
RECIPE-BASED PRODUCTION ORDERS
- feedstock recipe
- machine parameters
- mixer parameters
- fade in, special fade in
- premixes
- color setting
PRODUCTION RESULTS ANALYSIS
- daily, weekly, shift reporting
- output/input/loss representation
- throughput analysis
- batch-oriented material consumption posting
- recipe development and application engineering
RECIPE MANAGEMENT
- base formulations
- production formulations
- customer recipes
- calculation recipes
- sample formulations
- test formulations
RECIPE DEVELOPMENT
- recipe-based management of parameters for plant control
- color control of recipes
- creation of data sheets
- application-based recipe search (product finder)
- recipe families
LABORATORY
- management of laboratory orders
- integrated task management
- quality management
QUALITY ASSURANCE PRODUCTION CONTROL
- test methods
- standard test procedures, client-specific test procedures
- recipe test plans for the control of production-accompanying
- quality assurance
- recipe test procedures, group/family test plans, customer-specific test procedures
- interval types to control the inspection frequency
- time intervals, quantity intervals, container intervals, event intervals
- dynamization of test intervals
- requalification tests
- incoming goods inspection procedures
- container-oriented quality status management
- quality control station
- test certificate generation
- ash computer
COMPLAINTS MANAGEMENT
- finished product
- input materials
QA ANALYSIS
- control charts
- statistical analysis values
- advanced Quality Data Exchange Format
- safety data sheets
- integrated task management
Sales module
- compound-oriented customer and prospect management
- recipe-based calculation module
- quotation generation
- customer-specific price lists
- potential and project management
- integrated task management
- compound-oriented quotation management
- rule-based price update
- index-based rules
- RE-safeguarding rules
- powerful customer pricing module
- module: Sales Planning
- visit report management
Contract manufacturing
- order type subcontracting
- ordering and goods receipt of customer provisions
- mapping of subcontract recipes (customer material, own material)
- production accounting (input material consumption record for subcontracting)
- proof of consumption of customer material for subcontract orders
- customer stock lists
REPORTS, KEY FIGURES & ANALYSES
ERP data warehouse with powerful business intelligence functionality across all areas of the ERP systems
- reports
- automatically sendable reports
- adhoc reports
- analyses
- key figures
Using the powerful ETL loading tools, further data from external systems can be integrated into the data warehouse (e.g. accounting and controlling, personnel and time management).
Analysis examples:
- Sales analyses
- Gross profit analyses
- Inventory analyses
- ABC analysis
- ABC / XYZ analysis
- Inventories
- Customer inventories
- Inventory comparisons
- Incoming order analyses
- Order backlog analyses
- Delivery analyses
- Purchasing analyses
- Supplier evaluation
- QA analyses
- Recipe analyses
- Production analyses
- Downtime analysis
- Productivity analyses
- Sales and potential analyses
General application features
TECHNICAL FRAMEWORK CONDITIONS
- client-server solution
- mobile devices for ERP control in logistics and production
- MS-SQL database
LEGAL CONTROL
- flexible rights management at user group and individual user level
- display restriction of lists according to definable criteria (e.g. according to sales region)
POWERFUL USER INTERFACE
- free user configuration of favorite menus
- free filter and sort function for all tables
- user individual configuration of tables All tables can be configured by the user according to their (number and order of columns, column width, color formatting)
- users can create multiple user-specific configurations for a table
- each table can be exported and printed
OFFICE INTEGRATION
- excel export of all tables and reports
- MS-Word export of all reports
- e-mail dispatch of all documents
- fax dispatch of all documents
- interfaces
INTERFACES
- WMS interface (PSI -warehouse management)
- WIZCON (plant visualization)
- outgoing invoice interface accounting
- invoice receipt interface accounting
- EDI
- Q-Stat
Poly.ERP is an ERP system developed for recipe-based production of compounders, masterbatchers and recyclers.
- Polymer-Chemie
- Polyblend
- TechnoCompound
- PolyMIM
- Polymer-Chemie Rus
- Sun Alloys Europe
- Masterbatch Winter
- Polimarky
Further references and case studies can be found at https://www.polyerp.de/en/references/.
