Handicraft manufacturing enterprises are typical discrete manufacturing enterprises. The production process of products is usually broken down into many processing tasks, and each task only needs a small part of the enterprise's ability and resources. Enterprises generally organize raw materials and equipment with similar functions into some production organizations (departments, workshops, teams, etc.). ) according to the space and administrative management. In each department, from one work center to another, workpieces are processed in different types.

Compared with industries with high degree of automation such as machinery, chemical industry and electronics, handicraft production enterprises have the following obvious characteristics:

& ampOslash's single product is relatively simple, but there are many kinds of products, and a large number of new samples need to be developed according to market trends every year;

& ampOslash takes order production as the main operation mode. When customers place orders, they often involve personalized needs such as sample replacement, packaging, accessories and reassembly sets.

& ampOslash An order often involves multiple varieties, with many single and small varieties;

& ampOslash's whole production process is mainly manual operation by workers, with little use of automatic machinery and equipment, and the production capacity largely depends on the number and proficiency of workers;

& ampOslash's workshops have many online orders at the same time, so it is difficult to obtain raw and auxiliary materials according to the orders;

& ampOslash basically adopts piecework-based salary management, and there are also some hourly salary methods;

Main problems faced by handicraft production enterprises

& ampOslash scattered and missing sample data

For handicraft enterprises, sample information is one of the most basic and important information, because it is an important basis for production planning, material demand and procurement of the whole enterprise, and also plays an important role in the process of customer quotation and sample delivery tracking. However, due to the huge number of samples, customers often request to modify the samples. At present, most enterprises have such a problem. The data of molds, blanks, process wages, raw and auxiliary materials, packaging and auxiliary materials in the sample files are scattered in the hands of various departments or personnel, which often leads to incomplete sample data, untimely update or errors in data transmission from business processes to production departments.

& ampOslash production planning is difficult, inefficient and ineffective.

Because there are many kinds of goods in the order, customers require individuation, and the production process of products involves many processes, production managers need to spend a lot of time just to decompose the specific production tasks of the order, and it is difficult to have the energy to comprehensively consider the balance of production capacity and production schedule between goods and processes, and it is difficult to arrange production plans reasonably, which leads to frequent rush of goods and continuous falling into a vicious circle;

It is difficult for & ampOslash to track the production progress in real time.

Because there are many orders produced at the same time, there are many kinds of goods in a single order, and the production process involves many processes, it is difficult to grasp the actual production progress in time by relying on manual management, and it is found that a certain commodity number cannot be delivered in time when delivering.

& ampOslash's salary calculation is heavy and inefficient.

Handicraft enterprises generally have many employees, and at the same time produce many kinds of products and many production processes, and orders are often produced across months. Therefore, piece-rate wage is a labor-intensive and time-consuming job, and it is difficult to ensure the accuracy of the data, and it is also difficult to control possible wage black holes such as over-production registration and deliberate transfer of output by resigned employees.

Difficulties in cost analysis of & ampOslash

The actual production process of handicrafts is full of variables, from the mode of mold opening, the actual number of molds put in, to the actual practice of each process, such as rework, damage, compensation, wage adjustment and so on. The data of actual production process is often inconsistent with the data of sample development and design, and the actual purchase prices of raw and auxiliary materials, packaging materials and auxiliary materials may also change. In addition, semi-finished products and products stay in various workshops and processes without the help of system data.

ERP solution of Yixing handicrafts

Considering the production control points of handicrafts with different materials, the characteristics of product data are quite different. Over the years, our company has tailored a number of successful cases for different industries, covering resin handicrafts, daily/craft ceramics, fabric industry, toy industry, wood products industry and so on. In particular, the ERP system of Yixing resin industry has been successfully applied in many well-known enterprises in the industry, laying a good foundation for the long-term sustainable development of enterprises.

Overview of main functions and characteristics of ERP system in Yixing resin industry

Product BOM management

1. Packaging Method Management: maintains the sub-item combination method of the packaging item number.

2. Green body structure management: maintaining the green body splitting mode of products, supporting the same green body and supporting formula management;

3. Mold management: maintain the mold data of products, including all mold-related data such as mold opening mode, number of holes, times, silicone dosage, etc.

4. Process price management: subdivide into blanks, maintain all process price data of blanks, support process material management, and support packaging and assembly price accounting;

Working hours can be calculated according to the working price, and the working price can also be calculated according to the working time;

5. Cost accounting:

1) mold cost: comprehensively and accurately calculate the material cost according to the amount of silica gel, gypsum material and various auxiliary materials, calculate the mold cost combined with the mold opening price, and calculate the mold cost allocated to a single blank according to the number of uses;

2) Slurry cost: according to the formula proportion, calculate the dosage and cost of resin, gypsum and filler, and calculate the cost of red and white additives at the same time;

3) Wage expenses: including grouting, grinding, trimming, etc. In the molding stage, paint, draw eyes, paint, varnish, etc. All wage costs such as assembly and packaging in painting stage and packaging stage;

4) Packaging cost: realize the cost of inner box, middle box and outer box, as well as the cost of protective materials such as bubble bags and styrofoam, and the cost of packaging accessories such as egg lattices, partitions, sealants and packaging tapes, and calculate the single packaging cost according to the whole case packaging cost and packaging rate;

5) Fitting cost: Calculate the fitting cost according to the usage of product fittings;

6) Other costs: accounting for various additional costs such as management fees and taxes;

Production planning management

According to the personalized demand of customers when placing orders, the production task list is automatically generated according to the order BOM;

Combined with the inventory quantity of white materials and pigments, the automatically generated production task list indicates all processing information including mold opening quantity, blank production quantity, blank material formula, blank required number of each process, labor price and so on. And the production task list can be directly distributed to each workshop to arrange production;

Combined with capacity analysis, reasonably arrange the on-line time of the process and prompt the bottleneck process;

Workshop operation management

A well-designed output registration module, with a scale of 2,000 workers, only needs 1 special input personnel to register the daily production report of all processes;

Built-in over-production prompt function when registering daily output;

A variety of workshop picking management modes, supporting single picking or combined picking function, and supporting separate material deduction function;

Support personal piece counting and assembly line piece counting;

Built-in damage compensation management module;

Semi-finished products warehousing and picking management;

Production schedule tracking

Provide real-time query function of order production progress in various ways, and you can fully understand the production progress details according to order-item number-blank-process;

Production balance analysis, which comprehensively analyzes the production schedule balance data between the item numbers in the order and between the processes in the item numbers;

Early warning prompt of production progress, which automatically reminds the article number that may be behind according to the shipment plan of the order;

Order purchase management

Automatically analyze the purchase quantity of packaging materials and accessories according to the order variety, quantity and personalized demand of packaging materials and accessories;

According to the analysis results of purchase quantity, combined with material classification and supplier type, the purchase order corresponding to each supplier is automatically generated;

Analysis of actual production cost of order

The actual production cost takes into account the situation of damage compensation, the actual purchase price of raw and auxiliary materials, the adjustment of process wages, the actual delivery of molds, etc. , and automatically calculate the actual production cost of each order;

Salary accounting management

The system automatically extracts personal piece-rate wage registration data, assembly line registration data (including assembly line scoring and work score registration), personal picking data (including all kinds of pulp collection records and auxiliary material picking records), hourly wage registration data, employee reward and punishment records, attendance, accommodation, catering and other data provided by the administrative department, and automatically calculates the piece-rate wages of all workers in combination with calculation rules;

Overview of main functions and characteristics of ERP system in Yixing ceramic industry

Compared with other handicrafts, the production process of ceramics is more difficult to control because of the high temperature firing process. At present, the information management level of ceramic production enterprises, especially the fine control level of production process, is generally low, and the means of cost control are lacking, so it is difficult to eradicate the cost waste of each link in the production process.

Our company has successfully developed an ERP management system for the ceramic industry through the full cooperation with Chaozhou Yuri Ceramic Manufacturing Co., Ltd., which has raised the production management level of Yuri Company to an unprecedented new height, realized the meticulous management of all links in the whole production process, systematically controlled all kinds of losses and wastes, and steadily improved the production efficiency.

Yuri Company is the leading enterprise of China craft daily-use porcelain, which is famous for its product development ability. It develops a large number of patterns and patterns every year, and the complicated process is typical. The products are mainly medium and high temperature, and the products are mostly designed by carving and sending flowers. Modeling methods include grouting, pressing and rolling, and patterns include decoration such as baking, painting, colored gold and underglaze color.

The operators of Yuri Company have a full understanding of computer information management, and began to use computer systems to gradually manage the production process in the 1990s. However, due to the complexity of the process, it has been difficult to effectively control the production cost. Although some production data can be counted in time by simple production management software, it cannot fundamentally solve the problem of cost control. During this period, the company also adopted the ERP products of a well-known domestic company, but due to the particularity of the industry, despite the full cooperation of all staff, after nearly a year of efforts, it still failed. After learning from a painful experience, Yuri Company found Yixing Company to develop a set of ERP management system for it. Yixing developers did not bear the great trust, and finally provided a very successful ERP management system for Yuri Company, which solved the cost control problem that has plagued the company for many years.

ERP characteristics of Yixing ceramics;

ERP of 65438+ Yixing Ceramics starts with the yield analysis of each link, comprehensively considers the pattern factors, firing temperature and decoration requirements, and uses statistical principles to collect and analyze historical production process data, so that it can basically and accurately give suggestions on the number of green bodies when ordering production, thus reducing the cost at the source;

2. The analysis and control of the firing cost are realized: the firing cost accounts for a high proportion in the porcelain cost, and how to reduce the firing cost is an important factor to control the production cost. In the firing cost, different kiln equipment and firing temperature curve have great influence on the firing cost, and another factor that can be improved is the reasonable kiln loading density. In the case of multi-type co-firing in one kiln at the same time, this factor is most likely to cause the fluctuation of firing cost due to human factors. Yixing Ceramic ERP provides the monitoring function of kiln loading data, which can effectively avoid unreasonable kiln loading density and reduce its cost in seconds.

3. Use the defect analysis system to find out avoidable defect factors and accurately distinguish the responsibility of defects, so as to systematically control the waste caused by human factors and analyze the defects caused by materials such as porcelain clay and glaze water in time;

There are many factors that cause porcelain defects, but many of them can be effectively avoided. For example, unqualified bricks can be found in time during the blank inspection, and the green bricks that are definitely burned should not be transferred to the kiln workshop for firing. After the green body is fired, the green body should be inspected, and the firing defects of the green body should be cleaned and repaired in time. Don't bring the blank burning defect into the glaze burning stage. The kiln worker should clean all kinds of kiln furniture in time and keep the kiln furniture clean to reduce the slag falling defect.

To reduce the defects caused by human factors, there is a premise that the responsible person can trace back accurately. It is through this that the defect analysis system in Yixing ceramic ERP greatly reduces the defects caused by human factors, thus laying a solid foundation for cost control;

4. Workshop benefit accounting system, Yixing Ceramics ERP can accurately calculate the monthly production benefits of various departments, accounting granularity reaches the component level, accounting methods are distinguished between products and finished products, accounting content covers all expense items, accounting accuracy reaches the level that can really be used for performance appraisal, making the system reach the height that can effectively mobilize the enthusiasm of managers, which is also the core value of Yixing Ceramics ERP. At present, there is no other ceramic management software in China that can reach this height;

5. Other functions of Yixing Ceramic ERP:

1) built-in fuel cost calculation formula can basically and accurately predict the fuel cost of porcelain in various kiln environments and various firing temperatures;

2) Built-in decal cost calculation function, which can calculate the decal cost of various colorful porcelain products;

3) Mold cost calculation function, which can automatically calculate the processing price and material cost of the mold according to the mold type;

4) Track all processing, quality inspection and handover processes of products from molding to packaging and warehousing, and grasp the current status of all products online in real time;

5) The bar code scanning technology is adopted to realize the function of fast and accurate registration of all kinds of data. The workshop supervisor issues the processing task list with bar code to the employees through the system, and after completion, the data is collected into the system in real time by scanning the bar code, which fully guarantees the efficiency, accuracy and real-time performance of data entry, thus providing a guarantee for all kinds of data analysis and progress monitoring; This is also an important basis for the successful application of the system. If the data entry workload is large, the efficiency is low, and the accuracy cannot be guaranteed, it will be difficult for the system to play its role.