QAD Manufacturing Inventory Control Software

QAD provides innovative manufacturing inventory control software applications for leading global manufacturing companies. QADManufacturing Inventory Control Software applications are designed to simplify the management and enhance the efficiency of manufacturing resources and operations both within and beyond the enterprise. QAD Manufacturing Inventory Control Software is the core foundation for numerous modules that make up the complete QAD Enterprise Application suite.

QAD's manufacturing inventory product is made up of four primary functions: Product Data Management, Manufacturing Planning, Manufacturing Execution and Advanced Features.

Along with these core features, QAD offers various add on modules that enhance the core functionality for our customers that have specialized and more complex manufacturing environments especially for manufacturing inventory control. All these modules fully integrated with QAD Manufacturing core.

• QAD Lean
• QAD Just In Time Sequencing
• QAD Production Scheduler
• QAD PRO/PLUS
• QAD Planner

QAD Manufacturing: Inventory Control: Planning

Manufacturing Planning includes the planning processes of production planning, master production scheduling, material requirements planning, and capacity requirements planning. Feedback is provided by the execution processes so that planning can be kept valid at all times. It includes:

• Product Line Planning
• Forecasting
• Master Scheduling
• Resource Planning
• Materials Requirements Planning
• Capacity Requirements Planning

Product Line Planning for Manufacturers

Product Line Planning allows the entry of forecasts for future shipments, orders and production as separate plans for groups of similar items or products which can then be reviewed and adjusted based on the relationships between them.

• Plan by product line rather than individual item
• Plan shipments, production, inventory, backlogs, and gross margins—all measured by overall sales and cost to ensure that the plan meets all the financial needs of the business

Forecasting for Manufacturers

Forecasting uses statistical methods and extrapolation techniques to evaluate underlying patterns in sales history data to predict future demand. Forecasts are used to develop the master production schedule and drive material requirements planning (MRP).

• Supports forecasting of items at the site level
• Enables multilevel master scheduling by forecasting items at the family item and planning or option item levels
• Allows calculation of simulated forecasts by analyzing an item's shipment history data and producing a forecast detail record that predicts what quantity of the item will be sold in the future (simulation capabilities for what if analysis)

Master Scheduling for Manufacturers

Master Scheduling drives the overall planning process, creating and maintaining shipment forecasts and master production schedules. Demand from various sources such as long-range forecasts, discrete sales orders or repetitive demand is considered in the planning process.

• Analyze production plans for capacity and level-loading constraints prior to executing the full regeneration of MRP
• Create and manage master schedules in a fully automatic, fully manual, or computer assisted mode
• Support multi-level master schedules
• Synchronize demand with plan to reduce inventory levels

Enterprise Resource Planning (ERP) for Manufacturers

Enterprise Resource Planning (ERP) provides manufacturers the ability to evaluate the feasibility of a production plan or master schedule, providing a basis for adjusting the plan or adding resources.

• Check resource loads for both the product line plan and the master schedule
• Verify that there are enough resources to produce the projected quantities
• Validate the production plan and master schedule before submitting them to MRP for detailed planning

Material Requirements Planning (MRP) for Manufacturers

Material Requirements Planning provides time phased requirements for production and procurement based on firm and forecast demand. Tools are provided to manage the materials planning process by exception and automate procurement and production releases.

• Calculates projected inventory, schedule, and planned orders by utilizing a site's master schedule, and all other sources of demand and supply
• Performs MRP planning activity by site. completely independently from inventory, demand, and supply at other sites
• Produces action messages to automate the purchasing and production release processes

Capacity Requirements Planning

Capacity Requirements Planning uses the planned manufacturing schedule to analyze the requirements placed on manufacturing work centers. It compares these planned requirements with the capacity available to determine if a production plan is feasible. If a work center is over capacity it will identify the production that is causing the problem to facilitate rescheduling or adding resources to the work center.

• Determines work center load and generates capacity-requirements plans for a department, work center, or machine by utilizing MRP planned orders, other work orders, and repetitive schedules
• Expresses work centers/machine requirements in hours and reports within a user-specified time periods based on days, weeks, or months

QAD Manufacturing Inventory Control: Execution

QAD Manufacturing Execution fully manages mixed-mode manufacturing environments with a set of integrated modules that control all activities on the production floor, from identifying missing parts to reporting labor. Immediate feedback is provided on status, shortages, quality problems or other issues critical to production performance. It includes:

• Inventory Control
• Physical Inventory
• Work Orders
• Repetitive
• Quality
• Shop Floor Control

Manufacturing Inventory Control

Inventory Control tracks and controls purchased material, stocked items, work in process and finished product in a single integrated inventory control environment. It creates inventory transactions such as unplanned issues, receipts or inventory transfers to act as the foundation for on-hand balances for use in both planning and financial valuation

• Track inter-site transfers and automatically post financial transactions
• Track batch/lots and serial numbers
• Manage shelf life and controlled locations

Physical Inventory Management

Physical Inventory manages physical stock counts either manually or with the addition of scanning devices.

• Counts are manually recorded with inventory tags, then tag counts are entered to update live inventory balances
• Works off a frozen image of inventory thus allowing inventory to be counted without stopping operations

Work Orders Management

Work Orders manages the release and production of specific product orders to the shop floor.

• Allows for multiple release and control techniques
• Allows splitting and recombining work orders to better manage inventory
• Specific Work Order Bills ensure that as-built can be tracked and impromptu changes to production recorded as they occur.
• Compare and report manufacturing cost variances that reflect actual performance to engineered standard costs and to frozen standard costs
• Create work orders through inventory management software system for configuring items directly from a sales order
• Support co-product and by-product manufacturing
• Report production and labor only where desired
• Support lot and serial number traceability, substitute material usage, and alternate routing and work centers

Repetitive Inventory Scheduling

Repetitive supports repetitive or rate based scheduling of high volume items through clusters of work centers grouped into virtual production lines. This method allows rate based scheduling and finite forward capacity management along with line changeover and maintenance scheduling.

• Streamline labor and material planning and reporting for products manufactured in high volumes
• Control the manufacturing process through the use of a quantity-based build schedule
  

Quality Management for Manufacturers

Quality Management defines and records the quality of product including inspection and testing during the manufacturing process, incoming inspection of purchased items, and inventory sampling.

Quality Management contains definitions of standard testing procedures, applies tests to work orders and repetitive schedules, holds quality test results, and manages inventory sampling plans and quality work orders. Throughout the production process, testing procedures may be devised and routed along with the product.

• Include test instructions quickly and easily in work order documentation and repetitive schedules
• Monitor test results, along with production progress information
• Base tests on standard definitions of testing procedures included with the system
• Manage inventory sampling plans and quality work order
• Devise and route testing procedure along with products throughout the production process
• Support, Advanced Product Quality Planning (APQP), Product Planning and Approval Process (PPAP), supplier quality, shop floor quality, and sales and PO receipt transactions.
• The foundations for in process recording of quality results for cGMP requirements

Manufacturing Shop Floor Control

Shop Floor Control tracks activities and records operations status and labor times for manufacturing Work Orders. Shop Floor Control uses the work order routing to calculate usage variances, efficiencies, and utilization.

• For Repetitive environments .rate, usage and method variances for both labor and burden are calculated at the time labor is reported and may be posted immediately or held until the work order receipt is processed.
• Supports labor reporting from shop floor devices

QAD Manufacturing Inventory Control: Advanced Features

Outsourcing / Subcontracting Manufacturing Inventory Control

Outsourcing/Subcontracting allows repetitive operations (including shipping transactions) tied to supplier schedules to anticipate when outside processing steps are due and plan them as would be necessary for any other component purchased.

Control Inventory with Lot Serial Traceability

Lot/Serial Traceability provides complete lot and serial number tracking history from finished goods back to the supplier's lot.

Adds extensive lot/serial tracing and reporting functions to Work-in-Process (WIP) and generates tracing information at the operation level whenever registered resources are consumed or produced.

• Supports regulatory compliance in areas such as Waste Electrical and Electronic Equipment (WEEE) and Recycling of Hazardous Substances (RoHS)
• Provides critical traceability required to comply with food security regulations and track potential contaminations and affect rapid notification or recall if required. Supports traceability needed to support Hazard Analysis and Critical Control Point (HACCP).
• Provides the critical foundation for traceability mandated for cGMP compliance with ability to control and status lots (including attaching quarantine and not fit status to lots).
• Provides the foundation to support product liability tracking for warranty recalls and investigation

Bar Codes and RFID for Inventory Control

Bar Codes & RFID capabilities allow for labels to be scanned and for real-time transactions to be captured (i.e. Purchase Order Receipts, Work Order/Repetitive Schedule completions, etc.). Scanned bar code data is validated which eliminates the manual entry of data.

• Supports all global labeling standards as well as integrating into data repositories such as GS1 (formerly EANnet and UCCnet).
• As RFID initiatives mature, QAD is focused on supporting them and offers a solution based on current best practice.
• Supports the needs for Aftermarket manufactures as well as foundation for returnable containers by vertical

QAD manufacturing inventory control software is the core foundation for numerous modules that make up the complete QAD Enterprise Application suite. QAD manufacturing inventory applications are designed to simplify the management and enhance the efficiency of manufacturing resources and operations both within and beyond the enterprise.