BatchMaster Manufacturing for SAP Business One

BatchMaster Manufacturing for SAP Business One, designed for the manufacturing industries in the UAE and Middle East, has a number of capabilities for formula management, including:

• Formula comparison
• Version control for tracking formula changes
• Rollback to regain the saved/previous version of formula
• Sizing formula by weight or volume
• Material substitution by weight or volume percentage, availability of a material etc.
• In-process quality checks for better formula management
• Formula analysis with various available cost options
• Support multilevel formulas
• Intermediate expansion to replace the intermediate or by-product involved within the formula

Bill of Material or BOM shows the detailed and hierarchical view of end product, right from the raw materials used, intermediate, packaging materials, etc. It links the formula with the finished goods or intermediates, and also enables to specify routing. Moreover, it also includes features like:

• Comprehensive Bill Of Material functionality
• Encloses top level BOM item
• Flexibility to define Fill Level in desired unit of measurement
• Routing functionality for flawless production process
• Serve multiple packaging options
• Bill of material report to classify the top assembly items, assembly types, and status of the BOM components associated with the formulas
• Cater your needs for both Process (Formula BOM) and Discrete (Assembly BOM) Manufacturing
• Dispatches full view of the BOM hierarchy
• Single BOM allocation with multiple formulas

The module assists you in changing your formulas into more effective and preferred ones in a safe and efficient manner. It has a number of features, including interactive analysis of formula physical properties, and a variety of other characteristics, such as:

• Keep the specifications of your intermediates current according to the formulations using the Intermediate Property Rollup Utility
• Conveniently compare several formulas and products side-by-side from same screen using the Comparative Properties Analysis
• Create completely new physical properties based on combination of material specification and operators available using the Physical Property Formula option
• Overcome the hassles of creating a new formula from scratch using the Physical Property Analysis option
• Reduce the time and efforts invested on R&D of new formulas

With the following functionalities, BatchMaster Manufacturing for SAP Business One increases compliance efficiency for industries, allowing them to proactively comply with FDA and GMP requirements.

• Supports Data Ownership Authorization
• Generates Nutritional Label/Nutritional Information Panel using different serving sizes and unit of measures
• Generation of Ingredient Statement, quantity and percentage wise
• Reports for
  • FDA Audit
  • Quality Control History
  • Lot Tracking
  • Transaction
  • Lot Explosion
• Embedded forward and backward lot-traceability feature
• Generates Lot Recall Letter
• Facilitates Lot strength to calculate potency of the product
• Attach Standard Operating Procedures.
• Closed loop process that maintains FDA 21CFR Part 11, cGMP, Bioterrorism Act etc.

The production module offers a complete set of tools that streamline the entire process from beginning to end. It integrates effectively with operations and delivers real-time data, allowing it to manage a variety of tasks such as mixing, filling, and assembling components. Other distinguishing characteristics are:

• Expedite production scheduling and generate real-time information faster than ever before using the Production Scheduling Dashboard
• Streamlined batch sizing, improves accuracy of inventory and costing functions immensely
• Resolve the common process manufacturing necessity of producing a batch and its low-level intermediates in a single operation, using the Super Batch functionality
• Acquire running totals of your finished goods and by-products yielded and consumed
• Get your costs and inventory updated in real-time with the closure of your batch

BatchMaster Manufacturing for SAP Business One’s fully integrated Lot Traceability feature precisely tracks the forward and backward movement of raw materials, intermediates, and finished goods across the supply chain. As a result, producers are better equipped to meet all compliance standards and remain audit-ready.

• Manage any recall situation within fraction of time
• Diminish response times to potential complications, which can eventually certify brand security
• Confirm the transparency all over the value chain, from ingredients to consumer goods
• 360 degree view into a product lot’s activity
• Ensure each lot remains distinct in subsequent operations
• Wide-ranging lot traceability with container level tracing of source supplies

Automatically generates Safety Data Sheets that are entirely compliant with government reporting requirements. The SDS module allows you to gain complete control over the SDS formats you use and how you keep them current, as well as the option to generate custom templates that describe the components and their appearance sequence. Its one-of-a-kind design allows you to customize it to your own requirements.

• Define and associate safety information for inventory items, formulas, customer order, production order etc.
• Achieve Hazard Communication Standard, Superfund Amendment and Reauthorization Act (SARA) Title III compliance
• Preserve Occupational Exposure Limits per component using the Material Safety and CAS Number screens
• Indicate which ingredients are to be listed on your MSDS based on Material Hazard Type in number of ways
• Use the built-In USA format to generate your MSDS or create your own templates as required
• Generate schedules for group of MSDS to organize their generation
• Create a bunch of MSDS boilerplates that are to be printed on an MSDS by using Supplementary File
• Track MSDS printing dates for item and customer combination

Boost the organization’s quality control. We offer precise quality-focused solutions to assist you in achieving optimal quality control at every level of your business, from sourcing raw materials to manufacturing intermediates/finished goods and inspecting final goods before delivering to clients.

This fully integrated quality control system keeps track of pass/fail statistics for an unlimited number of user-defined criteria, and assists you in accepting or rejecting products based on inspection findings.

• Well defined QC functionality to receive, produce and ship products that meet customer and compliance requirements
• QC test and sample definition plus ability to determine the target values, control limits and maximum allowable defects
• Accomplish the QC sampling process with Pass/Fail results, Alphanumeric as well as Numeric values
• Immediate and counteractive action, like destruction, return etc., can be taken against the items that fail QC Inspection
• Track the faulty materials and consign them for return to vendor, scrap, or rework.
• Supports the tracking of production quality, expiry date, shelf life period, and lot controlled products.
• Reporting the QC results for Raw Material, Intermediate and Finished Good Item.

BatchMaster Manufacturing’s Costing module lets you to pick the most accurate, realistic, and profitable price for your items. Examine the formula and finished product costs from a variety of perspectives and at various levels of detail.

Change the variables to show how labour, overhead, materials, and packaging affect the final cost of the product. Manipulate the quantity of any material to do a “what-if” analysis and evaluate the profitability of alternative scenarios based on different assumptions. Right instantly, see how the change affects the costs.Collaboratively analyze costs associated with the manufactured products

• Collaboratively analyze costs associated with the manufactured products
• Establish gross margin based on costs and selling price
• Revise formula loss factors to accomplish better accuracy
• Calculate Sales Price and Standard Cost based on the cost of ingredients
• Revaluate Actual cost of the finished good or intermediate inventory
• Modify and scrutinize overhead, labor and material quantities efficiently

Identify production bottlenecks based on expected deliveries and distribute resources properly to avoid overburdening situations. The Production Scheduling Board is a one-stop shop for all of your production scheduling needs. A dynamic graphical user interface that clearly displays batches with different stages using separate colour codes can be used to monitor and analyse production floor inventory and resources.

• Reschedule the batches just by dragging them to the preferred schedule date, on the Schedule Calendar grid
• Define tasks that needs to be executed apart from the routine production jobs
• Interactive month, week and day views provide flexibility to swiftly organize the batches accordingly
• Quickly list the batches and illustrate their relationship to one another using the Gantt Chart View
• Zoom-in the Schedule Calendar Grid of the Production Schedule screen and get details of the process cell attached to the existing Batches/Orders/Task
• Regulate planning and scheduling of activities on the shop floor

Using the Routing module, you may use your abilities to flawlessly plan and control the manufacturing process. Specify the order in which work centres are used during the manufacturing process. Quick Labor Entry can be used to keep track of employee and machine information, as well as preparation and processing times. The routing module is a great place to start when it comes to categorizing manufacturing routes.

• Designate shifts available by weekdays in which the selected employee will be working
• Define and generate schedules for a range of employees for selected working days
• Plan and manage resources by interpreting the schedule of a given work centre over a week’s span using the Work Centre Capacity Utilization option
• Add routing to a particular BOM just by implementing very easy setup options.
• Cope with item routings by means of the Routing tab present on the Batch Ticket form
• Firmly retain completion time and quantities related to production batch by means of various routing facilities

Multi-site manufacturers can manage their bins with BMM for SAP Business One. The bin level, rather than the warehouse level, is where all company operations, such as sales, purchasing, and production, are managed. This feature ensures that the goods is carefully handled before being placed in the bag. You can see a real-time display of products in stock for any inventory transaction. If you keep inventory in numerous containers, you’ll be able to keep track of it more quickly and precisely.

• Track inventory bin wise, item wise, warehouse wise, lot wise or container wise
• Support multi-location inventory feature to organize your warehouse or multiple warehouses
• Get an instant view of various bin transactions, such as Container, Bin Number, Issue/Receipt Quantity etc.
• Handle non-tracked inventory with ease at bin level
• Manage various Storage Conditions for bins and items
• Warnings for older lots and duplicate lots
• Expired lots calculation for issue transactions

BatchMaster’s MRP module assists production managers in scheduling and placing orders for dependent demand items, as well as assuring a flow of materials required for production, by determining what to order, when to order, how much to order, and when to schedule an order’s delivery.

• Ensure material availability and increase planning stability
• View production bottlenecks at a glance with interactive graphical vision
• Reconcile the customer requirements with plant capacity, material availability and vendor capabilities
• Support in evaluating the effects of schedule changes in short run
• Perform scheduling on single or range of items and warehouses
• Spontaneously create Purchase Order for the re-sale type of item
• High stock levels and reduces storage costs
• Last minute rescheduling and efficient allocation of resources
• Planning Time Fence to protect the master plan from spontaneous changes
• Adjust dates of planned orders that falls within the planning time fence

Establish a timeline for developing items, obtaining supplies, and contributing value to the manufacturing process as quickly as possible. BatchMaster can assist you in developing and maintaining a successful manufacturing strategy based on sales predictions, purchase and production orders, inventory statuses, and work orders with detailed bills of materials. Its execution ensures the availability of production inputs and the readiness of products for shipping. BatchMaster MRP supports you in determining material requirements by inflating the BOM and time phasing supply with the stated average lead times.

• Streamline the production operations and minimize unplanned interruptions to improve performance
• Confidently sustain with the lowest possible material and product level in stock
• Robotically generates purchase orders from net demand relative to reorder levels
• Aligns existing jobs with changes to required dates
• Supports the top, bottom and smart level explosion
• Supports to meet the delivery schedule, purchase activities and plan orders
• Avoiding the delay in material procurement, production and decision making
• Cost of excessive inventory can be reduced