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Manufacturing management

IPL Consulting develops and provides solutions for discrete and project production manufacturing based on Infor’s industry-specific ERP solutions and reflect all the needs of enterprise-level and medium-sized businesses.

We provide solutions that help industrial companies transform even the most complex manufacturing processes into a competitive advantage and create the manufacturing system that allows to manufacture products that meet individual customers’ needs with near mass production efficiency.

We help our customers to build a manufacturing system for all discrete manufacturing types ETO, MTO, MTS and repetitive, that ensure agility, flexibility, and integrated product life cycle management.  

Usually customer-focused manufacturing companies use several types of production, including MTS. IPL Consulting solutions allow to combine various scenarios of production management/ planning and customize the system to the specific enterprise needs.

Project production management (PPM) (Engineer-To-Order)

  • Building a holistic end-to-end project and production process management system
  • Operational management of design and operational documents development
  • maintains project and engineering documentation integrity, monitor workflows, provide project status in real-time
  • Synchronization of design processes and Engineering Document Management with production
  • Management of project works with detalization by its composition (WBS). Maintaining a single end-to-end work schedule
  • Management of project costs within the context of object elements
  • Management of project’s resourcesand materials budgets, labor input budgets
  • Planning of procurement and production in accordance with project schedules and needs of the project work
  • Management of project’s inventory with borrowing/reimbursement options

Customer-focused manufacturing management (Unit Effectivity, Make-To-Order, Assembly-To-Order)

  • Product configuration management
  • Master data management as a basis for Industry 4.0
  • product lifecycle management
  • Demand forecasting and safety stocks calculations
  • Analysis of the resource’s utilization and calculation of planned capacity utilization
  • Calculation of the resource’s utilization and planned utilization of capacities
  • Specification of critical capacities and materials
  • Order acceptance: сconfigure, price and quotation
  • Customer order management
  • Management of assembly units’ completeness
  • Quality management, built-in analysis of quality deviations impact on the result
  • Service management
  • End-to-end supply chain visualization — from production through shipment, service, warranty, and refurbishing

Management of multi-tier distributed companies

  • Movement or transfer material or items between sites or warehouses
  • Consolidation of data from sites at financial entities
  • Shipment to common customers and receive from common vendors
  • Share administrative functions between sites
  • Centralization of payment processing (between sites having the same currency)
  • Visualization Accounts Payable and/or Accounts Receivable transactions across sites
  • Creation of items at one site for multiple sites
  • Visualization of item availability across sites
  • Creation of vendors at one site for multiple sites
  • Creation of customers at one site for multiple sites
  • Creation of purchase orders at one site for multiple sites, allowing for accumulation of like items to get quantity breaks from vendors
  • Demand and source vendor site PO-CO processing automation

Foundry management

The solution solves main task is to prevent low-quality castings from entering the further production stream and supports strict technological control of the entire production process.

  • Casting Quality management related on complete digital data of manufactured units in the foundry
  • Establishing stable processes based on analytics of castings quality statistics
  • MPS planning for good quality castings and casting bushes on the molding line
  • MRP planning for all semi-finished products
  • Reorder point planning on core section
  • Incoming inspection for the main purchased materials
  • Short technological routes usage, with division into semi-finished products (justified by the topology of production)
  • Unique items movement tracking by assigned numbers
  • Batch traceability and batch accounting of steel
  • Allocation of only basic materials to the BOM

MRO management (Maintenance, Repair and Overhaul)

  • Creation of a “digital product passport” for maintaining the service BOM (for a series or modification)
  • End-to-end product lifecycle management:
    • Tracking of Engineering Document changes through all the product lifecycle
    • Tracking of the BOMs of product by identifying number
  • Registration of the actual product structure during the initial acceptance and defect detection of the product
  • Changes registration in the physical product structure in the process of replacements, installations and removal of parts, sensors, or assemblies
  • Tracking the operating time and state of the product nodes and the product as a whole
  • Tracking of specific product nodes through serial numbers and support of separate cost accounting (government, commercial projects, etc.)
  • Annual and operational planning of repairs, of procurement and production in accordance with project schedules, current needs and retrospective data of past periods works
  • Service Terms & Warranties Management
  • Incident & Call Center service management
  • Field Service Management
  • Service and Factory Repair Management
  • Repair quality management
  • Complaints management
  • Analytics for all levels of management:plan-fact analysis at all stage of end-to-end product repair execution
    • defective items report,
    • fault detection report,
    • report on costs and estimation of the cost of repairs in the context of products