In some of our previous articles, we looked at specific ERP capabilities, their applications in industrial manufacturing, and how they can help companies build responsiveness, quality, and control.
Today's post will examine one of ERP's most popular features; Batch control module.
A high-level overview of the batch control workflow
A batch is a specific number of components or sub-components with common characteristics such as quality, supplier, potency, age of use, etc. Controls allow manufacturers to assign a particular number to each lot and track each stage of the production process in ERP software, from the start of the purchase order, through production, to the completion of the sales order.
Batch control begins when you receive raw materials from a supplier. Everything downstream can vary from process to process, but a common denominator among all our manufacturing customers is the need to enter specific batch information during the production process.
ERP's batch control gives manufacturers quick and easy access to specific batch information when they need it.
With ERP, our goal with each implementation is to simplify and limit the total number of manual inputs that users have to make when entering and tracking batches through the system. This saves users from having to dig through multiple screens to find the right batch, saving a lot of time and reducing errors. Ultimately, the flexibility of batch recording, coupled with the flexibility of the ERP system, enables the batch tracking process to move through the production process in a seamless and non-invasive manner.
Batch control - from "good to have" to "Must include"
Our customers love this level of tracking functionality because it allows them to pinpoint exactly where to look when a product in production doesn't meet specifications. This is a requirement for manufacturers in highly regulated industries such as pharmaceuticals, food packaging, and aerospace, where companies can be subject to severe penalties and lawsuits if their products do not meet strict standards.
For each customer, we look for specific ways to customize batch records and integrate them directly into production.
Even in industries that don't face strict regulations, manufacturers are starting to look for batch control features because they make scheduling and planning easier, as users can know exactly where each component is at any given time. In addition, the ability to track batches through the production process helps ensure that only the highest quality products reach customers, as defects can be traced back to their source and remedied as soon as possible.
For example, the USA recently partnered with a customer that manufactures specialty refractory products. Some of its products sell for more than $10,000 each, so if a product comes out of the oven with a big crack, the company needs to know exactly what's wrong. An investigation into the cause of the break will lead to an assessment of all raw materials that entered the product and, more specifically, the exact batch involved in the order. ERP reduces survey time from days to minutes by making large amounts of data easily accessible, ensuring timely conduct.