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Sage 200 Manufacturing
In today’s tough economic environment, particularly in the manufacturing industry,
you need to remain competitive. Sage 200 Manufacturing can provide an ideal solution
for manufacturing businesses that helps you control every stage of the manufacturing
process from planning, materials and costs to tracking orders and collecting payment.
Part of the Sage 200 Suite, our manufacturing software is built on the Microsoft
® .NET platform and is a powerful manufacturing, financial and trading solution
whether your manufacturing processes are simple or complex. Sage 200 Manufacturing
offers the ideal ‘out of the box’ solution whether your manufacturing processes
are simple or complex.
From estimating through planning and production management, Sage 200 Manufacturing
software helps you to:
- Meet delivery times – by helping you control the production process.
- Manage your cash low – by helping you keep track of stock and deliveries.
- Control product quality – by tracking items all the way through production and delivery.
- Reduce costs – by helping you become more efficient through improved planning.
- Optimise production – by helping to create a lean supply chain.
- Save time - by creating purchase orders and works orders automatically from Material
Requirements Planning recommendations.
- Stay on track at every stage of production.
- Share information - see all the detail
needed to stay in control of the supply chain, from raw materials to finished products.
- Track deliveries accurately with 2-way or 3-way Goods Recieved note (GRN) matching.
…and much more
Integrated Operations for a Competitive Advantage
While efficient resource planning is pivotal to a successful manufacturer, being
able to quickly analyse facts and spot developing issues can make all the difference
to your proitability.
While tracking costs across departments or planning resources, having integrated
software would enable you to link your buying, inance, distribution and customer
facing operations.
By implementing the complete suite of Sage 200 software, your business would beneit
from simpliied ownership and a single point of contact and accountability. The components
of the suite are designed to work together, minimising interoperability issues.
Think how implementing the Sage 200 Suite would put you firmly in control of your
entire business.
Bill of Materials
The Sage 200 Manufacturing Bill of Materials module helps you create detailed Bills
of Materials (BOM) for all your manufactured products, no matter how many components
you use. BOMs may, in turn, use other BOMs (sub-assemblies) within them to provide
a multi-level, hierarchical structure. To learn more about Bill Of Materials click
Here.
Estimating
In today’s competitive environment, you need to minimise the time spen preparing
complete and accurate estimates for your customers.
The Estimating module in Sage 200 Manufacturing is a powerful tool that helps you
achieve this and also track every stage of production. Designed to assist in the
production of estimates for one-off items or non-repetitive batches, it provides
accurate and timely quotations of work. You can also create works orders, BOMs or
sales orders from your estimates.
Information from the estimate is drawn from the stock records in the Stock Control
module and from the Labour Register, Machine Register and Operations Register. You
can enter all expected costs for each stage of the job under each of the job cost
types.
The estimating module allows you to:
- Produce quotes for multiple batch sizes.
- Create accurate estimates quickly.
- Convert estimates into works orders with ease.
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Sage 200 - Estimating Key - Benefits.
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Quantity breaks – quote for multiple batch sizes
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You can build up an estimate using a variety of quantity breaks. You can alter the
quantity and quickly see how the totals are affected. You also have the ability
to cost the estimate and print the estimate details for any/all of the quantity
breaks that you have entered.
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Save time by using the same estimate to reflect different quantities and calculate
the different costs. For example, by creating an estimate for 1000, 5000 and 10,000
of a particular item.
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Print quotes directly from the module or via Microsoft Word ©
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The information entered against an estimate can be printed using the configurable
templates supplied or may be exported to Microsoft Word.
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Provides flexibility and greater versatility by accessing all the specialised word
processing features and formatting available within Microsoft Word ©
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Successful estimates can be converted to jobs and processed through MRP
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Estimates can be turned into jobs or into works orders without further data entry.
By using works orders you can ensure that you have suficient resources to complete
the manufacture within the allotted time.
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Take advantage of all MRP beneits, for example, use existing stocks, resource scheduling
etc.
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Unlimited estimating stages
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Unlimited stages give you the ability to control your estimating process.
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Increases flexibility and ensures that you are fully in control of your costs.
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Actual vs. Estimates – summary/detail
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You can view actuals vs. estimates on screen or by running a detailed report.
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Ability to drill down to the detail.
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Optionally create Works Orders, Sales Orders and BOMs directly from an Estimate
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Without any further data entry, an estimate can optionally create Works Orders,
Sales Orders and Bill of Materials records. In addition, you are prompted to create
stock items for all of the non-stock items that exist on the estimate.
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Fast option for simpler requirements and eliminates the need to re-key data.
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Rapid order entry
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The rapid order entry feature allows you to create estimates quickly and speeds
up the creation of multiple estimates.
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Allows your customer-facing staff to create quotes quickly and easily over the telephone.
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Planning - Master Production Schedule (MPS)
The planning features in Sage 200 Manufacturing provide all the functionality you
need to control material, labour and machine costs in a busy mixed mode manufacturing
environment. The MPS function will smoothly control production planning, works order
processing and resource management, with full traceability for materials tracking.
MPS reads demands and creates a master production schedule for production of inished
items and sub-assemblies that are sold separately. While reading demands, MPS looks
at items that are:
- Outstanding from sales orders in the Sage 200 Sales Order Processing module.
- Marked for release in ‘Make to Stock.’
- Unfulilled in sales forecasts.
- Required to fulfil estimates in the Estimating module.
In addition, the MPS functionality also processes non manufactured items, such as
those that have been bought, so that the Materials Requirements Planning module
can facilitate back-to -back ordering.
Planning - Material Requirements (MRP)
This information is then processed through the MRP module. MRP looks at stock projections
in relation to demands and generates appropriate recommendations by exploding demands
through the BOM levels to produce a series of ‘make’ or ‘buy’ recommendations. The
MRP module makes recommendations after considering supplier and BOM lead times,
stock levels, work in progress, on order quantities, minimum levels, batch sizing
rules, locations of stock components and whether version control is being used.
Each stock item can have an unlimited number of alternative suppliers, along with
lead times, cost prices, and suppliers’ part numbers and minimum order quantity.
Stock projection calculates predicted levels of selected stock items over any chosen
time period. When you have accepted the recommendations, the program will automatically
raise Works or Purchase Orders as appropriate. At this stage, you can also generate
Work In Progress valuations that can be manually or automatically updated.
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Sage 200 - Planning - Key Benefits
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Automatic creation of Purchase and Works Orders
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The MRP recommendations to 'make' and 'buy' products can be amended,
filtered and sorted, combined or split and then actioned to automatically create
Purchase and Works Orders.
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Improved eficiency by saving time and eliminating the need to manually key data.
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Powerful stock projection facility
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View a list of predicted stock for all or a range of products in each time period.
If Sage 200 is using multiple locations, you can also look at a range of products
from an individual warehouse. You can see stock predictions for products below minimum
level, those with negative stock, or those above maximum level. You can also drill
down and look at the details for a particular stock item.
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Gives you the advantage of identifying potential problems before they arise by providing
full visibility and control over future stock levels.
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Integrated with Sage 200 Graphical Planner.
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Graphical Planner works alongside MRP. It shows, graphically, the schedule of work
i.e. works orders and MRP ‘make’ recommendations, required to meet the demand.
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Quickly and easily analyse the impact of changes to due delivery dates and/or quantities.
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Multi-level tagging
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Find and view all tags and exceptions with a particular recommendation reference,
purchase order number, works order number or sales order number. The recommendation
originally selected is displayed in bold and all other linked recommendations are
shown in a tree view structure.
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Answers the ‘why are we making/buying this’ question. Identiies which sales order(s)
will be impacted when an item is late.
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Planning - Graphical Planner
Preactor International is the market leading specialist for planning and scheduling
software. Working in partnership with Preactor, Sage have created a graphical planning
tool that helps you to:
- Assess potential changes to production, by producing plans that show how, for example,
adding overtime or extra shifts would affect deliveries.
- Produce flexible schedules that work forwards from a start date or backwards from
a due date, to suit your needs.
- Identify resource issues easily and change plans to avoid hold ups.
- Choose the way you want to view completed jobs.
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Sage 200 - Graphical Planner - Key Benefits
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Integrated, single constraint planning tool
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Working alongside MRP, it shows graphically, the schedule of work, i.e. works orders
and MRP ‘make’ recommendations, required to meet demands and will allow your staff
to create an optimised, achievable production plan.
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Allows you to make the most eficient use of resources whether it be machines or
labour.
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‘What-if’ planning functions
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Different plans can be produced and saved for the same set of demands, so you can
assess the impact on resources, for example, if adding overtime or extra shifts.
Production can be sequenced and schedules may be produced based either ‘forwards’
from a start date or ‘backwards’ from a due delivery date. You can view complete
jobs by operation or individual resource schedules.
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Compare and assess the impact of different plans, for example, adding extra shifts
or machines. Resource bottlenecks can be easily identified and the plan manipulated
as required.
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Drag and drop operations on the graphical planning board
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The Graphical Planner allows you to directly manipulate your production plan on
the Gantt chart view by ‘dragging and dropping’ jobs onto alternative resources
or different timescales. You can view complete jobs by operation or individual resource
schedules. The Graphical Planner will automatically check and preserve the sequence
of operations and dependencies between sub-assemblies and their components.
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Easy manipulation of the plan allows the user to investigate alternatives and update
the schedules.
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View complete works orders or operation
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You can view complete jobs by operation or individual resource schedules. This enables
you to identify any delays and resource bottlenecks.
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Presents an immediate, accurate visual representation for the easy identiication
of opportunities to improve delivery times.
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Flexible, generic Preactor interface
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The Sage generic interface has been designed to enable users of any Sage manufacturing
software to take advantage of the added functionality available in the Preactor
product range. This encompasses Multi-constraint scheduling, Advanced Planning and
Scheduling (APS) and fully customised solutions.
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Easy upgrade to higher level Preactor solutions with more sophisticated scheduling,
and APS options if you have more complex production scheduling requirements.
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Works Order Processing
The Sage 200 Works Order module allows you to produce parts using components specified
on the BOM or in the estimate, following the process specified on the operations.
Works orders can be created automatically from MRP recommendations or entered manually.
Stock levels are automatically updated when you allocate and/or issue stock against
the works orders. You can then produce picking lists, route cards, operation cards
and job sheets. On completion of the works orders, stock is automatically updated,
enabling goods to be despatched immediately. There is also the facility to backflush through lower level sub- assemblies. This automatically issues all components
through each of the levels and places finished items into stock.
The Works Order module allows you to:
- Save time by creating works orders automatically from MRP recommendations.
- Avoid errors by automatically updating your stock levels when you allocate or issue
stock against orders.
- Improve eficiency by creating picking lists, route cards, operation cards and job
sheets.
- Save time by creating a single delivery note from multiple sales orders.
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Sage 200 - Works Order Processing - Key Benefits
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Works Orders generated automatically from MRP or BOM Trial Kitting or entered manually
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Works orders can be generated automatically in the following ways:
- Batch and one-off works orders generated from the MRP module.
- Batch works orders generated automatically from the Trial Kitting window in the
Bill of Materials module.
- One-off works orders can be generated automatically from the Estimating module.
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Improves eficiency by removing the intensive manual process and reducing the risk
of manual error.
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Print Route Cards, Pick Lists and Works Orders
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You can print four types of works order documents: Picking List, Route Card, Job
Sheet and the Operation Card. The picking list shows all the components required
for the build, the quantity required, and the bin location of the component. The
Route Card, Job Sheet and Operation Card show the same information in varying levels
of detail.
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Provides quick, accurate and clear instructions to production.
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Optional multi-level backflush
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The ‘Backlushing’ option enables users to complete a works order by issuing the
raw materials retrospectively, (Single Level), or, if it is a top-level works order,
to issue the materials retrospectively for all the works order sub- assemblies (Multi
Level).
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Simpliies transaction processing in high volume and fast moving assembly lines.
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Accumulate actual labour costs through manual entry or using the Operation Times
module
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You can enter progress and times of operations against a works order. For works
orders not created from an estimate (batch works orders), these entries are normally
made using one of the works order documents, for example the Job Card, Route Card
or Operation Card.
The Timesheets option offers the facility to post actual times and costs to
works orders. The facilities offered here are very similar to those provided by
Operation Times, but the information is entered from employee timesheets rather
than Route Cards, Job Sheets or Operation Cards.
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Enables you to maintain cost control, identify low contribution products and sustain
realistic proit margins.
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Record scrap of components and inished products
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You can scrap traceable inished items and allow replacement materials to be issued.
This may mean updating the production plan or raising new works orders or purchase
orders to meet the original demand.
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Enables your staff to accurately plan and cost out production.
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Produce Certiicates of Conformity
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Conirms products are manufactured to ISO quality standards.
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Prove your commitment to quality/attainment of quality standards.
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Tight integration with Sage 200 Commercials
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Works Order Allocations automatically update Sage 200 Stock Control.
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Maintains accurate stock records automatically.
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Operation Times – Shop Floor Data Collection (SFDC)
Working alongside the Works Order module, the operations time functionality in Sage
200 Manufacturing allows you to work more eficiently. It can print barcodes onto
items such as route and operation cards, so that operators log their jobs with a
scanner and the relevant works orders are automatically updated.
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Sage 200 - Shop Floor Data Collection - Key Benefits
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Log actual times against Works Orders |
You can enter progress and times of operations against a works order. For works
orders not created from an estimate (batch works orders), these entries are
normally made using one of the works order documents, for example the Job Card,
Route Card or Operation Card. |
Removes the manual process of timesheets – providing easy, accurate time
recording with minimal disruption on shop loor. |
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Actual vs. Estimate/ Standard |
View the costs entered and see the variance against what you had estimated for
an operation.
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Provides you with accurate costing and calculation of a job’s proitability. |
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Print work in progress reports
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The comprehensive reporting options show all activities and costs recorded
against a job.
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Stay in control of your costs by reporting in as much or as little detail as you
need at any time. |
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Update job information on the shop floor |
Operating in either ‘online’ or ‘retrospective’ mode, your staff can enter job
details, the time taken and the quantity completed using the keyboard or a
barcode scanner. |
Simple-to-use screens and scanner interface. Real time information promotes
better decisions. |
Materials and Finished Product
Traceability
Your customers are demanding
products of an increasingly higher
quality, and in many industries
legislation and adherence to quality
standards are becoming ever more important. All this requires complete
visibility across the supply chain.
Sage 200 Manufacturing helps you
track material from receipt through
your complete production process
to despatch, no matter how many
locations or components you use.
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Sage 200 - Product Traceability - Key Benefits
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Full batch and serial number processing |
The powerful ‘Find’ facility allows instant recall of any batch or serial number
record. If your processes involve issuing a batch number or serial number to
inished products, the software can record this, enabling you to trace it to the
customers who received it. |
Automatically maintains essential quality standards and detailed traceability |
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Allocate and Issue by batch/serial number |
The ability to track the movement historically of materials used in production
and manufacture of jobs, is normally by means of serial or batch numbers
assigned to the items. If you are using traceability and you have set up the
Stock Control module to allocate batch or serial numbers at despatch, you can
select the traceable items manually, for which issues are to be made.
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Provides lexibility by allowing the user to select which items are traceable. |
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Substitute one traceable component for another |
When using traceable items, you may be required to substitute the batches
actually used. This function facilitates the change and preserves the record or
batch movements and the actual batches used. |
Increases lexibility and relects real-life situations. |
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Record all batches/ serial numbers used in an individual Works Order |
Traceability of goods is determined by the ‘batch and serial numbered items’
settings in the Stock Control module. Batch and serial numbers can be assigned
when goods are received in the Purchase Order Processing and Sales Order
Processing modules. You are prompted to specify batch and serial numbers
whenever you allocate or issue stock within the Works Order module. Batch and
serial numbers are also created when completing works orders. |
Fast and eficient. Find data faster than with a manual system. |
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Find all batch or serial numbers used in one inished item |
Maintain a record of all batches and serial numbered items used in the
production of a inished item. |
Ensures your staff can quickly and easily ind information. Supports product
recall. |
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