BellHawk Online Operations Management System

Manufacturing Execution System

BOL-MES is a full capability manufacturing execution system (MES) BOL-MES is especially suitable for make-to-order and contract manufacturers who have to manage many quick turn jobs at the same time.

CAPABILITY

1. Production Tracking

Management

Routes Specify routes, with bills of material for each step/operation.
Visibility See real-time status of work orders and customer orders.

Work Orders

Documents Print barcoded "travellers" to track orders step by step.
Types • Service
• Manufacturing/Processing
• Assembly
• Test/Repair
Alerts Preempt mistakes such as trying to use the wrong material.
Time Track working time and elapsed time for each operation.

Inventory

WIP Track work-in-process material to the next operation by batch or by piece.
Materials Track for each operation:
• Production of work-in-progress materials or finished products,
• Unused materials returned to stock,
• Work in progress materials or products for rework.
• Reusable and unusable scrap,
Floor stock Auto-reduce as work product is reported out of each operation.

2. Inventory Tracking

Management

Visibility View real-time view status of raw, intermediate, and finished goods inventory. WIP Track work-in-progress in real-time.

Inventory

Number plates Identify containers with unique “license-plate” numbers.
Containers Track containers of the same material in multiple geographic locations.
Scope Track materials by:
• Container.
• Nested containers such as cartons on pallets.
• Serial number.
• Customer ownership.
• Location.
• Lot number.
• Expiry date
• Attributes (User Defined Parameters).

Movements

Goods-in Receiving and put-away of raw materials.
Goods-in Picking, packing and shipping of finished goods.
Trace Who handled each container of materials.
Return Unused material returned to stock.
Adjust Scrapped material and inventory adjustments.
Count "Cycle-count” validation by location ("Blind-count" audit module available)

Assets · Tools

• Puchase
• Location
• Issue to people
• Return
• Status
• Repair
• Valuation/Depreciation
• Disposal

3. Warehouse Management

Purchase Orders

Import Enter or import Purchase Order.
Receive Track receiving against Purchase Orders.
Part Numbers Translate Vendor Part Numbers.

Production Materials

Orders Generate Pick Orders from Work Orders.
Issues Pick materials for Production Operations.

Sales Orders

Import Enter or Import Sales/Ship Orders.
Process Handle Customer Sales Order Information.
Make-to-OrderGenerate Work Orders from Sales Orders.
Pick Orders Generate Pick Orders from Sales Orders.

Fulfilment

Track Record picking, packing and shipping of products.
Shipping Dock Record loading of trucks/trailers.
Documents Produce packing slips and manifests/bills of lading.
ASNs Generate of Advanced Shipment Notice (ASN) data for EDI systems

4. Operations Management

Machine/Line Tracking

Status Track the status of machines, production equipment or lines.
Times Record setup, run, downtime, and take down.
Allocate Materials, labour and machine time to multiple work orders running at the same time on a machine or line.

Activity Based Costing

Time · Materials Tracks the materials, labour and machine/line time used to make each product.
Job Cost Calculates the actual job cost and compares this with the predicted/standard cost.
Pricing Cost comparison indicates where future prices may need adjustment.

Real-Time Scheduling

Current Status MES knows the current status of each job from the data it collects.
Work Centre Schedules The system uses this status data to schedule each work centre in real-time. The aim is to ensure, as far as is possible, that work orders are completed on time.
Priorities The scheduling algorithm gives priority to jobs falling behind schedule. It also takes into account any user defined "importances" such as customer and urgency.
Rush orders Real-time scheduling accomodates rush orders and rework.
Job selection The work centre team will normally work on the first order in the list but, if they have a good reason, they can choose another.

Demand Driven Materials Planning

This process complements the longer range materials requirements planning functions of ERP systems.

BellHawk uses its bill of materials data to perform all the complex MRP calculations. It can also generate work orders and purchase orders. This avoids potential errors and saves materials managers a huge amount of time.

Materials managers use their knowledge to take the make or buy decisions.

Available Inventory Prediction
MES predicts time-phased available inventory in real-time:
• Starts with physical inventory,
• Adds materials to be ordered or made,
• Subtracts materials to be used on work orders,
• Subtracts materials to be shipped to customers.
Results
Foresee how many of each part will be available at future dates.
Make or Buy? Managers iterate through a series of screens deciding to make or buy.
• Start with a make-to-order items on sales order lines.
• Create work orders to make the finished products.
• Decide to make or buy sub-assemblies and parts.
• Continue until there are no more parts to be made.
• Create work orders and purchase orders.

PDF

System

Base System

Real-Time Operations Tracking System (RT-OPS)

Modules

Warehouse Management (WMS: PO · SO · PICK · SDO)
Equipment Tracking Option (ETO)
Real-time scheduling module (WCS)
Dynamic real-time materials requirements planning tool (DRP)