Syspro ERP for Manufacturing

SYSPRO’s ERP Manufacturing Process Management Software allows manufacturers to plan, execute & control production more effectively based on a wide variety of manufacturing modes.

SYSPRO ERP Supports Integration across all aspects of the Manufacturing Process.

SYSPRO enterprise resource planning (ERP) software supports the control, integration and synchronization of all aspects of the manufacturing process and accommodates both short and long production runs in the following manufacturing environments:

  • Discrete Manufacturing
  • Mixed Mode Manufacturing
  • Process Manufacturing
  • Make-to-Order
  • Make-to-Stock
  • Job Shops
  • Assemble-to-Order
  • Configure-to-Order
  • Engineer-to-Order

Manufacturers need to be agile, flexible and responsive. Manufacturing software deployed to manage the various processes must allow for synchronization and integration of manufacturing techniques. Whether manufacturing to order, to stock, using discrete or process methods, SYSPRO provides a full set of tools to help you plan, record, track and control your output. We ensure visibility throughout the manufacturing supply chain as well as integration with other systems in the production environment.

SYSPRO manufacturing software improves core competencies such as:
Managing inventory levels to optimize the competing demands of availability versus cost – Keeping your finished goods inventory to an absolute minimum. This assists in decision-making: what to manufacture, with what resources, when, where, and in what sequence.

Providing quotes that are accurate and keep costs under control – Ensuring the integrity of cost and profit calculation for bid processes. On confirmation of a quote, SYSPRO provides the capability to automatically raise all supply actions related to fulfilling the customer order. SYSPRO’s Product Configurator facilitates seamless rules-based order processing for assemble, configure and make-to-order products.

Defining bills of materials (BOM) from simple to very complex bills – Enables the definition of simple single-level bills through to complex formulations with multiple units of measure and relationship definitions.

Calculating lead and elapsed times, and order quantities – Ensures accurate calculation of lead times and dynamic elapsed times, and assists in the optimization of production order quantities. Engineering Change Control (ECC) facilitates the efficient management of changes to product versions.

Planning and scheduling of production – Efficient management and execution of re-scheduling activities when business priorities and plans change. Planning features include forecasting, master planning, material requirements planning and capacity planning. Scheduling functionality extends from single-constraint scheduling to multi-constraint scheduling and sequencing.

Material requirements and capacity planning – Material and labor consumed in production may be back flushed, or, for longer production runs, issued as consumed to work in progress. Work-in-progress inspection functionality enables a product to be receipted against multiple items if grades of the final product vary.

Managing material, labor and scrap during work-in-progress – Tracks actual versus estimated labor hours. Facilitates material usage and scrap.

Integrating with CAD and shop-floor data collection systems – Our integration framework enables version-independent integration to CAD and shop-floor data collection systems.

Cost control and tracking – Enables the capture, tracking and analyzing of job and product costs, and profitability in real-time. Provides expected versus actual costs for material and scrap, internal and external labor, fixed and overhead costs per job, or group of jobs. R&D job data is easily extracted for regulatory reporting requirements.

Performing ‘what-if’ modeling on material, labor and routing costs – Provides extensive costing control and tracking, including the facility to model the effects of what-if material, labor and manufacturing route costs. Evaluate job cost performance, margin analysis and pricing with full visibility to product cost details and profit margins, including for co- and by-products.

SYSPRO Bill of Materials facilitates an accurate expected cost against which to track actual production costs. The complete bill forms the basis for material and capacity planning, shop floor control and costing. You can create and maintain a model of your manufactured or assembled products as well as generate what-if costing scenarios.

The Bill of Materials system enables you to construct quantity or percentage relationships between assemblies (final product) sub-assemblies (bulk batches) and components (raw materials) using up to 15 levels and you can assign each component to a selected operation in the parent routing.

You can model the routing (i.e. the relationship between work centers and the time taken by the various elements of capacity usage) of the product to accommodate varying size batches, milestone operations, progressive scrap and dynamic elapsed times. The routing can also include information on tooling, operator skill levels, operation instructions, testing requirements, etc. Full bill of material costing and what-if costing facilities are provided, as well as the facility to calculate the cumulative and manufacturing lead times of an item and to update the relevant fields against the stock item.

Various types of bills can be added:

  • Planning bill
  • Batch bill • Single Level bill (kits)
  • Phantom part (part of a BOM for grouping purposes)
  • Notional part (part of a BOM for Co-Products)
  • Made-in bill

For more information related to SYSPRO’s Bill of Material offering please also refer to the following:

  • SYSPRO Engineering Change Control (ECC) – enables you to improve your management of engineering changes to your products. It enforces discipline and management control over modifications to bills of materials and shop floor routings.
  • SYSPRO Activity Based Costing (ABC) – enables you to more accurately apportion overhead costs to specific products, the aim being to associate elements of overhead cost to those products that actually cause the cost.

The Facts
The benefits of Bill of Materials

  • Intuitive tree-view display with operational Gantt Charts
  • Analyze BOM and ‘what-if’ costs
  • Compare BOM costs to current inventory costs
  • Identify material shortages with multi-level trial kitting
  • Support planning bills, phantom parts and sub-contract operations
  • Optional components supported for sales of kits
  • Track effectivity dates of components
  • Define scrap factors for more accurate planning
  • Define routes per location for accurate costing and planning
  • Plan for co- and by-products, apportioning costs accurately


Bill of Materials features

  • Supports up to 15 levels
  • Multiple recovery rates per cost center, work center and employee
  • Track time and capacity in different units of measure
  • Define component requirements up to 6 decimal places
  • Document routing instructions and component notes
  • Link pictures and videos to Bill of Materials
  • Validate structures and operations and provide notification of potential problems
  • Calculate BOM costs per warehouse
  • Define movement time between operations
  • Calculate manufacturing lead times
  • ‘Where-used’ query with ‘replace where-used’ function
  • Import structure and routings from third-party systems e.g. CAD
  • Calculate dynamic-elapsed time and capacity required
  • Transfer rolled-up BOM costs to unit cost of item
  • Indicate move time between work centers
  • Capacity calendar per work center and productive units
  • Define components as quantity per, % of parent or specific quantity regardless of batch
  • Indicate scrap percentage and/or quantity with optional progressive scrap
  • Define and process parent and component quantities in a unit of measure other than stocking
  • Update work center information when associated cost center information changes


Integration with SYSPRO

  • Inventory (Essential)
  • General Ledger
  • Product Configurator
  • Quotations • Requirements Planning
  • Sales Orders
  • Work in Progress


Audit trails and reporting

  • User-defined selection criteria for flexible reporting
  • Detailed ‘where-used’ reporting
  • Extensive BOM costing reports • Reports complete routing information
  • Trial kitting list highlights quantity requirements and shortages
  • Listings of manufactured parts with and without a structure attached
  • Various BOM profiles provided

SYSPRO Engineering Change Control helps you improve the management of engineering changes to your products and/or associated data. This is achieved through user-defined workflow, steps and processes, and can augment or replace the paper trail that usually accompanies any changes to product design data. The archiving facility enables retrieval and production of prior revisions/releases.

The Engineering Change Control system gives you ready access to documentation on prior product versions. In this manner, you can address questions relating to product defects in older product versions. Comprehensive ECC documentation also enables you to easily revert to the production of prior product versions, if necessary, to suit the requirements of a particular customer or conform to regulatory requirements.

If a product is under the control of ECC, then any maintenance to a bill of material and/or routing of the product can be accomplished only by means of a current Engineering Change Order.

Engineering Change Orders provides the mechanisms to:

  • Assign product design tasks to particular users (or groups of users)
  • Transfer tasks between users (or groups of users)
  • Notify users of new tasks
  • Remind users of outstanding tasks
  • Sign off engineering changes electronically
  • For more information related to SYSPRO’s Bill of Material offering please also refer to the following:

The Facts
The benefits of Engineering Change Control

  • Define workflow to document and control product design changes
  • Assign product design tasks to specific users/groups of users
  • Transfer tasks between users/groups of users
  • Define new task notifications, outstanding task reminders and electronic sign-off
  • Control BOM and/or routings maintenance with mandatory Engineering Change Order’s (ECO)
  • Optionally prevent creation or maintenance of purchase orders, jobs and sales orders for products on an ECO
  • Retrieve previous revisions of BOMs, routings and jobs from archives for production as planned or as built

Engineering Change Control Features

  • Govern revision/release sensitivity at stock code level
  • Keep track of product-related data such as drawings, circuit diagrams and CNC programs
  • Enforce security and controls in the ECC process
  • Govern the ECO cycle using meaningful user-defined status codes
  • Define any number of user-defined statuses with associated routings
  • Movement between statuses can be automatic or manual
  • Trigger an associated event when an ECO is moved into a status
  • Identify affected products against an ECO
  • Identify existing jobs, purchase orders and sales orders relating to the affected products on the ECO with where-used queries

Integration with SYSPRO

  • Bill of Materials (Essential)
  • Inventory (Essential)
  • Purchase Orders
  • Quotations
  • Sales Orders
  • Work in Progress

Audit trails and reporting

  • Report on status of all Change Orders
  • Report on all revisions and releases held against ECC controlled items
  • Listing of ECC users, Status Codes and Routings


SYSPRO Factory Documentation enables better management of factory production by providing factory production staff with clear and accurate user-defined shop floor documentation regarding the tasks to be performed and the materials required.

The Factory Documentation system enables you to define up to four different factory documentation formats for various uses such as:

  • Job tickets
  • Material requisitions
  • Route cards
  • Travelers

The Facts
The Benefits of Factory Documentation

  • Visibility of expected start and completion dates for each operation within a job
  • Enables you to set the expected duration of each operation
  • Provide production staff with routing instructions
  • Provide visibility of materials issued and operations completed, including quality control
  • Inform the production staff of the next operation to be performed (for routing) and provide routing instructions
  • Prepare job packs

Engineering Change Control Features

Defines up to four different factory documentation formats, such as:

  1. Job Tickets
  2. Material Requisitions
  3. Route Cards
  4. Travelers


  • Prints bar codes on documents for use with automated data collection devices
  • Includes operation instructions, technical notes and material notes on documentation
  • Prints material requisitions per operation or work center
  • Generates documentation for a range of existing jobs or for selected jobs
  • Produces documentation for dummy jobs for a specified quantity based on a standard Bill of Material
  • Reprints factory documentation as required
  • Includes stock code and job multimedia on documentation
  • Material requisitions for components

Integration with SYSPRO

  • Bill of Materials (Essential)
  • Inventory
  • Work in Progress (Essential)

Audit trails and reporting

  • Status flags are maintained to indicate whether documents have been printed for each job
  • Reprint documents if required


Families and Groupings is essential to an organization in a demand-driven environment and serves as input to MRP. SYSPRO Inventory Families and Groupings provides the tools to arrange ‘collections’ of stock keeping units (SKUs) into families and groupings of similar items. These collections provide a high-level view of items at which sales forecasts can be produced and the quality of the forecast measured. A significant feature is the ability to group warehouses for purposes of forecasting at a regional or territory level for logistical or supply chain purposes. There is also the feature where forecasts may be generated at a brand level to facilitate a clearer marketing picture.

Within SYSPRO, Families and Groupings refers to the various collections of inventory items that you have classified in a way that is meaningful to your business (e.g. you could classify a ‘filter’ as an OEM product, a spare, a paper filter, an oil filter, etc). The need for Families and Groupings arises from a business scenario where, owing to the number of stock codes or stock keeping units (SKUs) the forecasting of individual stock items would constitute an unmanageable workload. It also makes sense to ‘collect’ common stock codes into a family or group.

A family generally refers to a collection of SKUs where a hierarchy and a logical relationship exist between them. For example: Apple juice is packaged in 300ml, 500ml, 1L, 1.5L and 2L plastic bottles and would also be a member of the Pure Fruit Juice ‘family’. Families are best observed by examining an organization’s price list and are mostly used in the ‘outbound’ or sales view of the SKUs.

A group generally refers to a single level collection of SKUs that is used when arranging SKUs for storage or internal analysis. For example: the 300ml plastic bottle would be a member of the Plastic Packaging ‘group’ of SKUs. Groups are best observed by examining an organization’s logistics view and may be used to create ‘inbound’ (i.e. supplier) ‘home’ or ‘outbound’ views of collections of SKUs.

The Facts
The Benefits of inventory Families and Groupings

  • Establish families or groupings of SKUs using SYSPRO’s unique collections capability with hierarchical structures for Brand or Product Type views
  • Consolidate SKUs with different pack sizes using an alternate common unit of measure
  • Forecast at regional or territory level by consolidating warehouses for logistical or Supply Chain purposes
  • Aggregate sales history of the collection members to enable a forecast at collection level and then desegregate collection forecast back to SKU level
  • Facility to edit history at collection level
  • Variety of forecasting algorithms including a competition method which automatically selects the best algorithm for the collection
  • Forecast using sales value, cost value, quantity or gross profit as the basis
  • Detect seasonality and apply forecasts to seasonal data if present
  • Manually or automatically remove outliers and anomalies
  • Use SKU history of three or more years
  • Utilize monthly or weekly time buckets
  • Set forecast horizon up to 24 months
  • Configurable graphical output to improve visibility
  • Edit and optionally freeze draft forecast to reflect market intelligence

Inventory Families and Groupings Features

  • Very powerful Pareto (ABC) Analysis providing ranking of the items within each collection
  • Generates and reviews forecasts at various levels in the family hierarchy (with up to 15 levels)
  • Multi-level analysis of family performance over time
  • Analysis of sales value, gross profit, cost of sales, quantity sold or hits (invoice line occurrences) using very functional Pareto capability
  • Automatically updates collection history in real time
  • Compares manual forecast with computer recommended forecast
  • Controls and validates the forecast before activating in MRP
  • Sets default algorithms at company or collection level

Integration with SYSPRO

  • Inventory
  • Inventory Forecasting
  • Inventory Optimization
  • Requirements Planning
  • Sales Orders

Audit trails and reporting

  • Comprehensive audit trail of collection changes (add, change and delete audit)
  • Comparative reports and on-line queries
  • Pareto Analysis by sales value, cost value, quantity, profit value or profit %

SYSPRO Inventory Forecasting enables you to produce automatic or manual forecasts based on sales history as well as provide the tools to measure the quality of your forecasts. It uses a set of mathematical algorithms to predict future sales based on historic demand and enables you to easily identify those products that contribute the most to your business in terms of sales value, gross profit, cost of sales, quantity sold or hits.

The Inventory Forecasting system assists the enterprise in the following important areas:

  • It looks at past sales and matches the algorithm which would have had the best chance of success in estimating previous sales. That algorithm is then used to predict future sales.
  • The forecast can be manually edited, where required, taking cognizance of market intelligence and thereby improving accuracy and accommodating unusual demand. Thus organizations are able, through exception processes, to identify items by location which require manual correction.
  • It records Forecast errors to enable management to monitor and continually minimize those errors to acceptable corporate policy settings.
  • It is tightly integrated into the SYSPRO transaction based system. Therefore once the forecast has been approved, it becomes a current forecast.
  • The system automatically recognizes seasonal variations and accommodates those variations.
  • Large spikes in demand caused by unusual events such as export orders or stock outs can be automatically corrected by the Forecasting engine, through the use of standard statistic methods.
  • It allows for market intelligence input to better forecast future sales.
  • Since the system is better able to predict demand it will facilitate factory scheduling so that manufactures are better able to optimize their factory throughput while meeting the dynamics of the marketplace.
  • In addition, Forecasting can be performed at a level above the SKU, through the use of Families and Groupings, which allows for the logical grouping of items. Items can belong either to a hierarchical family structure or to a grouping across families or both.
  • Finally, the forecast engine produces a set of both tabular and graphical reports to assist in managing the forecast process. The most important of which is the ABC or Pareto analysis. This report combined with the Forecast Error report focuses management attention on the most important items in the organization and assists in addressing shortfalls in the procurement process.

The Facts
The Benefits of Inventory Forecasting

  • Set default algorithms at company, group of SKU-Locs or individual SKU-Loc levels
  • Ability to handle seasonality
  • Manually or automatically remove outliers and anomalies
  • Facility to edit history
  • Utilize monthly or weekly time buckets
  • Define multiple calendars
  • Set forecast horizon up to 24 months
  • Improve visibility with configurable graphical output
  • Edit draft forecast to reflect market intelligence
  • Easy identification of the items that contribute most to the business through Pareto Analysis
  • Store three or more years of history and purge unwanted history
  • Use of proxy to forecast items with no history
  • Review forecast accuracy to measure and improve the quality of forecast


Inventory Forecasting Features

  • Forecast generated at item/warehouse level
  • Variety of forecast algorithms including a competition method
  • Batch updating of forecast parameters
  • Analysis of product performance at stock code, warehouse, product class, supplier, planner or buyer levels
  • Analysis of sales value, gross profit, cost of sales, quantity sold or hits (invoice line occurrences) with Pareto
  • Automatic updating of forecast history from sales in real time
  • Enhanced data selection sets that carry through the entire process into Inventory Optimization
  • Powerful Pareto (ABC) Analysis
  • Forecasts in batch or manually with system suggestions – manual forecast items typically need market intelligence, or are of critical importance to the business
  • Compares the manual forecast with computer recommended forecast
  • Controls and validates the forecast before it becomes active
  • Converts approved forecast to current forecast within Requirements Planning
  • Edit history to exclude specific invoices, outliers or make manual adjustments
  • Identification of difficult to forecast items with a powerful review of achieved forecast accuracy

Integration with SYSPRO

  • Inventory
  • Sales Orders
  • Requirements Planning
  • Families and Groupings
  • Inventory Optimization

Audit trails and reporting

  • Complete audit trail of forecasts (create, change and update audit)
  • Simple workflow for forecast authorization
  • Reports/query screens for comparing forecasts
  • Pareto Analysis by cost, selling value, profit or unit measure

SYSPRO’s Inventory Optimization (IO), together with Inventory Forecasting, Families and Groupings and Requirements Planning, provides the tools and the processes to ensure there is sufficient stock in the right place, at the right time.

Inventory is one of the biggest assets within most companies yet it does not always receive an appropriate amount of management attention. There are good and bad reasons to hold inventory, so organizations need to understand what is contributing to their inventory and why. The role of inventory in the performance of a supply chain should also be understood for effective management.

SYSPRO Inventory Optimization takes a holistic approach to balancing the supply chain by providing visibility and understanding of the different parameters that create and shape inventory. The IO module allows users to create policies that determine how changing these parameters impacts on target inventory levels. This enables the best mix of services to the customer at the optimum cost of inventory to achieve that service. Seasonal and trend factors can also be incorporated.

The Facts
The Benefits of Inventory Optimization

  • Allows modeling of different ‘what-if’ policy scenarios to arrive at the best mix of service and inventory investment
  • Provides clarity and objective measures of when stock is ‘right’ (supply and demand are in balance)
  • Provides optimization at the SKU-Loc (stock keeping unit – location) level which can be aggregated up to higher levels
  • Forecasts at regional or territory level by consolidating warehouses for logistical or supply chain purposes
  • Improves stock turns and service levels
  • Reduces waste in the supply chain
  • Highlights where the problems are – stock-outs, over- or under-stocking
  • Improve ability to manage demand

Inventory Optimization Features

  • Use of selection sets common with Inventory Forecasting
  • A powerful forecast accuracy review
  • View and edit all the inputs to target stock (setup, policies, forecast, historic demand, forecast accuracy) in one interface, the IO stock model
  • Define fixed or risk based policies to determine the target stock at SKU-Loc level
  • Fixed policies can define minimum stock level as a quantity or days cover
  • Risk policies use Poisson or normal distribution for target service level
  • The maximum stock level can be defined from the order frequency
  • Create of draft stock levels at the SKU-Loc level
  • Approval of stock levels into live for use in Requirements Planning
  • Review excess stock (as defined by the SKU-Loc policy setting) and create SCTs (supply chain transfers) to re-distribute excess

Integration with SYSPRO

  • Integrates with the following modules:
  • Inventory
  • Inventory Forecasting
  • Inventory Families and Groupings
  • Sales Orders
  • Requirements Planning

Audit trails and reporting

  • Comprehensive audit trail of changes (add, change and delete audit)
  • Comparative reports, reviews and on-line queries

SYSPRO Inventory enables effective customer servicing and improved profits by providing superior inventory that optimizes stocking levels.

It forms the core of the accounting, distribution and manufacturing facilities and is designed to integrate with all the major functions of the systems and to provide flexible reporting on inventory holdings. All movements against inventory items are recorded and can be reported on. Features include multiple warehouses and bin numbers, multiple costing methods, a full Kardex facility, a stock take system and extensive reporting.

The Facts
The Benefits of Inventory

  • Effective control of supply and demand
  • Powerful queries include history and graphics
  • Flexible pricing and costing options
  • Identify key suppliers of items
  • Specify approved manufacturers
  • Extensive serial tracking with expiration dates

Inventory Features

  • Replenishment rules by item
  • Available to Promise calculation feature
  • Cost method defined per warehouse (average, standard, last, LIFO, or FIFO)
  • Retain cost in unit of measure other than stocking
  • Powerful pricing options (quantity, discounted, contract pricing, and more)
  • Globally change cost and selling prices
  • Track transfers between warehouses
  • Order policies and order modifiers defined at warehouse level
  • Multiple bin locations specified per warehouse
  • Multiple units of measure per item
  • Optional two-phased receiving
  • Backflush items with short manufacturing cycles
  • Lead times and dock-to-stock for realistic time-phasing
  • Record notes per item for purchasing, sales and manufacturing, including technical specs and dangerous goods handling
  • Place stock codes on hold
  • Robust physical inventory system
  • Cross-reference supplier and customer stock codes
  • Assign same serial number to multiple items
  • Browse stock items using multimedia images
  • Group inventory items into sales kits
  • Calculate minimum quantity based on usage
  • Facilitate bar code integration
  • Extensive security options for maintaining Inventory information
  • Actual cost tracking for lot traceable and batch serialized items
  • Ability to reserve stock

Integration with SYSPRO

  • General Ledger
  • Activity Based Costing
  • Sales Orders
  • Purchase Orders
  • Forecasting
  • Families and Groupings
  • Product Configurator
  • Return Merchandise
  • Trade Promotions
  • Blanket Sales Orders and Releases
  • Bill of Materials
  • Engineering Change Control
  • Requirements Planning
  • Lot Traceability
  • Quotations
  • Work in Progress
  • SYSPRO Factory Scheduling
  • Business-to-Business Trading
  • SYSPRO-to-SYSPRO Interface

Audit trails and reporting

  • Comprehensive audit trails for all transactions
  • Detailed inventory movement reports with flexible run-time options
  • Interactive valuation with graphical representation
  • Various exception reports to streamline analysis
  • Purchasing worksheet to assist buyers
  • ABC Analysis facilitate efficient management of resources

SYSPRO Lot Traceability enables you to maximize quality control through the tracking and replacement of any defective materials. It caters for the tracking of materials through their receipt, manufacture, assembly, inspection, stocking and final distribution, while maintaining quality assurance certification and tracking expiration dates. It also facilitates efficient and effective recalls.

The Lot Traceability system is designed to provide full traceability at transactional level for items that could cause loss of life or limb if quality standards are not adhered to.

Companies in highly-regulated industries for safety or health compliance (e.g. electronics, aeronautics, defense, food, pharmaceutical, medical devices and motor vehicles) would typically benefit from the Lot Traceability system. Integration with SYSPRO’s other modules permits full upward and downward traceability through all inventory transactions.

The Facts
The Benefits of Lot Traceability

  • Maintain a history of traceable items for accountability and customer service follow-up
  • Keep detailed notes about inspections
  • Provide reject control and documentation
  • Furnish shelf-life control
  • Trace semi-finished or finished products from the supplier of raw materials through to the customer
  • Optionally allow the same lot number to be used for multiple stock item
  • Archive information on traceable items to conserve disk resources
  • View an on-screen query of current and/or archived data

Lot Traceability Features

  • Query by item use (which customer, invoice, job, etc.) or by item supplied (which supplier, purchase order, stock item)
  • Trace serialized and non-serialized inventory items
  • Automatically or manually assign lot numbers as goods are received
  • Default lot number to work order number for easy traceability
  • Document all rejects and scrap
  • Locate data when lot or serial numbers are not known with flexible search program
  • Optional auto-depletion of lots
  • Optional full or sample inspection of lots during purchase order and work order receipts
  • Ability to reserve lot numbers to manufacture in Work in Progress
  • Ability to reserve component lots for specific jobs
  • Optional tracking of lots from component to parent

Integration with SYSPRO

  • Inventory
  • Purchase Orders
  • Sales Orders
  • Work in Progress

Audit trails and reporting

  • Extensive reporting in detail or summary
  • Report on current and/or archived costs

SYSPRO Product Configurator offers multiple configuration options to customers in a controlled, cost-effective and user-friendly manner in order to maximize customer service and operational efficiency.

It enables manufacturers to differentiate their product offerings through the customization of product to meet customer specifications and can help reduce configuration errors, while also reducing the involvement of experts in routine transactions.

The Product Configurator provides a rules-based configurator that will primarily help companies efficiently process products that are manufactured-to-order, assembled-to-order or sold in many configurations. It can also help reduce configuration errors, while reducing the involvement of experts in routine transactions.

Pre-defined user configurations are set up to control the configuration process and eliminate invalid product options and options relationships. The configuration can be set up to create a stocked parent part, non-stocked parent or both. Once the parent has been defined, non-technical people can use a Wizard to create a viable customized product for a bill of material, job, sales order, estimate, quote or a combination of these. You can also retain libraries of commonly configured items.

The Facts
The Benefits of Product Configurator

  • Ensure viable products with rules-based configurations
  • Improve order entry by being able to configure complex products on the fly
  • Provide an option to configure a standard inventory item
  • Maintain a library of common configurations to easily recall repeat orders
  • Calculate configurations based on the dimensions selected
  • Ideal for engineer-to-order and configure-to-order environments

Product Configurator Features

  • Define selection criteria to determine the number of options presented for configuration
  • Store and recall commonly used configurations
  • Selection criteria can be optional or mandatory
  • Selections may be dependent on other selections
  • Generate labor requirements based on configuration options
  • Develop component dependencies based on options
  • Create availability of critical items before processing
  • Prevent premature use with under development indicator
  • Optionally create a new inventory part and BOM from configured selections
  • Optionally generate custom work order and linked sales order
  • Drive demand through production by generating sales orders for standard parts
  • Print selections on order documents
  • Links the options to stock codes and operations
  • Option to generate non-stocked items or kit types
  • Generate intelligent part number based on selections
  • Base costs on bill of material or inventory cost

Integration with SYSPRO

Integrates with the following modules:

  • Inventory (Essential)
  • Accounts Receivable
  • Sales Orders
  • Bill of Materials
  • Quotations
  • Work in Progress

Audit trails and reporting

  • Check the gross profit of the configured items to ensure profit remains within acceptable limits
  • Test the configurations to verify that all the available options are dealt with accurately
  • Define invalid selections to verify that each configuration complies with technical requirements
  • Check the availability dates for resale products

SYSPRO Projects and Contracts facilitates accurate profit reporting for long-term projects that require analysis of costs and revenues at each section or level of the contract or project.

Purchase orders, job activity, sales orders and invoicing for jobs attached to a project update the contract or project in real time.

Query screens and reports show up-to-date actual and committed costs, realized and projected profit at any level of the job hierarchy.

The Projects and Contracts system caters for progress Billings, deposits and retention. You can define schedules against which progress Billings must take place and the method of Billings.

For deposits, you can record the deposit when accepting the contract and when you bill the customer you can indicate what portion of the billing value should be deducted from the deposit amount.

For retention, you specify the required retention amount as well as the retention period when creating the contract. Once the retention period is reached, you can invoice the customer and offset the retention value against the billing being made.

The Facts
The Benefits of Projects and Contracts

  • Establish the profits already taken against the job and the projected profit at the end of the job
  • Highlight profitable areas within a job
  • Identify profitable jobs within a contract
  • Compare real-time, actual, and committed costs assigned to a job
  • Show real-time, realized, and projected profits
  • Perform comprehensive reporting for jobs and/or contracts that extend over a period of time
  • Drill-down to transaction detail with job query
  • Query jobs in terms of sales, Billings, cost of sales and future expected costs
  • Maintain standard hierarchies
  • Analyze at job or contract level
  • Create deposits, retention and billing schedule based on different criteria

Projects and Contracts Features

  • Query (or report on) the current status of a job in terms of sales (orders placed by a customer) Billings (invoices raised on the customer) cost of sales of the Billings and the future expected costs
  • Query the total costs for a hierarchical job, including details of the head/section costs
  • Assign multiple jobs to a contract for tracking purposes
  • Estimate cost and revenue by levels or sections within a contract
  • Designate up to five user-defined costing levels within a contract.
  • Define costing levels within a contract
  • Assign unlimited numbers of heads to a contract
  • Assign unlimited numbers of sections and sub-sections to a head
  • Describe the costing hierarchy at the time of creating the job or estimate
  • Reduce processing time by recalling standard costing hierarchies for similar items
  • Attach purchase order lines to the relevant hierarchy level
  • Associate material labor transactions with the relevant hierarchy level
  • Recognize revenue through Sales Orders based on the costing hierarchy
  • Adjust billing values between heads and sections
  • Base flexible billing on contract or job hierarchy
  • Apply deposit against first, last, or any progress payments
  • Reduce final invoice by retention value
  • Raise retention invoice after specified term

Integration with SYSPRO

  • Accounts Receivable
  • General Ledger
  • Inventory
  • Purchase Orders
  • Sales Orders
  • Quotations
  • Work in Progress

Audit trails and reporting

  • Contract and job progress reports
  • Job transaction detail report
  • Estimate detail reports
  • Comprehensive audit trails
  • Graphical analysis of hierarchy costs per contract and per job

SYSPRO Quotations provides the flexibility of producing quotes with multiple offers for stocked and/or customized (estimated) items for existing or prospective customers. The power of this system becomes evident when one or more stock items must be specially made. In these cases a supporting estimate can be created. This, in turn, may have one or more special parts, which again can be supported by an estimate, and so on. This process can be extended to fourteen levels, which are then rolled up to complete the quotation’s top level costing.

The Quotations system enables the entry and maintenance of quotations, the printing of free-format quotations and, upon confirmation of the quote by the client, the confirmation of the details into Work in Progress, Sales Orders and Purchase Orders. The Quotations module generates quotes, which emulate sales orders, with up to five quotation quantities per line.

Prices are calculated through price mark-ups based on a percentage of individual labor/material costs, and/ or using a specified rate indicator for labor and/or using an entered price for material. In addition three global markup percentages can be entered all labor, material and the total.

When the quotation is accepted, it can be used to record a sales order and, where necessary, a chain of master and sub-jobs to support it. Purchase requisitions and purchase orders can be created for special bought-out items or when shortages exist for bought-out items anywhere in the sales order/job chain.

Besides using the Quotations module for quoting, SYSPRO has a simplified quoting system that can be used within Sales Order Entry, called Quick Entry. You use the Quick Entry function to enter quotes in a rapid and effective manner without having to enter all the details associated with the entry of a normal order. It is ideally suited to a telesales environment, where speed of entry is important and the facility to enter a quote rather than an order is vital. The quote can be stored for retrieval at a later stage and then converted into an order for a specific customer.

The Facts
The Benefits of Quotations

  • Quote on existing and/or custom items
  • Retain Bill of Materials for custom manufactured items
  • Retain supplier contracts for non-stocked purchased items
  • Provide access to the Product Configurator at line level
  • Identify time and materials for manufacturing an item
  • Estimate expected labor, material and overhead costs
  • Safeguard profits with built-in profit margins
  • Retain analysis on lost quotes
  • Selectively include quotations in MRP for planning
  • Generates quotes that emulate sales orders

Quotations Features

  • Recall non-stocked item information for use in multiple quotations
  • Determine price and lead-time with on-line cost roll-up
  • Define multiple formats for printing quotes
  • Control quoted costs with expiration dates
  • Five offers per quotation with default quantity breaks
  • Re-value based on current inventory or BOM costs
  • Copy and modify previous quotation
  • Import from CAD-generated files (or other ASCII files)
  • Recall configurations previously defined using the Product Configurator
  • Entry and maintenance of quotations
  • Print free-format quotations
  • Automatically create work orders, purchase orders, sales orders, retention, deposits and billing schedules on acceptance of quote
  • Job chaining for multi-level custom Bill of Materials
  • Automatically issue lower jobs to their parent, on completion
  • Add and print notes, comments and instructions on reports and quotation formats
  • Create inventory items and generate Bill of Material from estimate
  • Optionally consider progressive scrap on calculation of material and capacity requirements

Integration with SYSPRO

  • Accounts Receivable
  • Inventory
  • Sales Orders
  • Purchase Orders
  • Bill of Materials
  • Requirement Planning
  • Work in Progress

Audit trails and reporting

  • Retains quotes for as long as required
  • Detailed and summarized reports available
  • Estimate details may be included in quotation reports
  • On-screen queries show all quote and estimate details
  • Analysis reporting available

SYSPRO Requirements Planning uses projected demand and supply to assist you in planning and creating realistic production, purchasing and supply transfer schedules. It also identifies capacity constraints, and maintains optimal stock holdings in a multi-site and multi-warehouse environment.

The Requirements Planning system (with its online MPS and Job, Purchase Order, and Supply Chain Review programs) enables straight-forward conversions of the suggestions from the Requirements Calculation results, to live data. It is a bucket-less system which provides the facilities to run ‘what-if’ scenarios. Variable planning intervals and user-defined planning horizons offer further flexibility.

Dynamic capacity profiling, load leveling and single-level forward finite scheduling enable you to assess the impact of suggested jobs on your existing capacity loads.

The Facts
The Benefits of Requirements Planning

  • Meet demand with effective planning of required material and production capacity
  • Identify usage of critical resources with rough-cut capacity planning
  • Easily create build schedules from Master Production Schedule (MPS) suggestions
  • Suggest purchasing, production and transfer schedules to satisfy demand
  • Create and amend purchase orders and jobs based on suggestions with powerful, on-screen reviews
  • Test plans before updating the live system with snapshot’ functionality
  • Control inventory levels by identifying potential over-supply
  • Avoid bottlenecks by reviewing average queue times
  • Manage lot traceable items including tracking expiration dates
  • Preview reports to screen and email capabilities
  • Quickly identify overloaded work centers
  • Critical resource queries facilitate effective planning

Requirements Planning Features

  • Calculate material and capacity requirements under an infinite or finite capacity assumption
  • Create actual purchase orders, work orders or requisitions from suggestions
  • Generate supply chain transfers from suggestions for transfers between warehouses
  • Accept suggested changes to existing purchase orders and jobs based on changes in demand
  • Detailed pegging information available in queries and reports
  • Define Gross Requirements rule per item
  • Define planning frequencies, lead times and planning horizons for time fence indicators
  • Query MRP calculation results with pegging details
  • View capacity load in a bar chart or report form
  • View and report planning details in any time period with bucket less environment
  • Optional inclusion/exclusion of requisition users

Integration with SYSPRO

Integrates with the following modules:

  • Bill of Materials
  • Inventory (Essential)
  • Inventory Families and Groupings
  • Inventory Forecasting
  • Purchase Orders
  • Quotations
  • Sales Orders
  • Work in Progress

Audit trails and reporting

  • Comprehensive reports include Capacity Loading, Material Requirements, Suggested Work Orders, Suggested Purchase Orders, Pegging and Resource Requirements

    Action Reports include:

    • Build Schedule
    • Capacity
    • Forecast
    • Job
    • Purchase Order
    • Sales Order
    • Safety Stock

  • Calculates projected available and available to promise
  • Provides review of late supplies

SYSPRO Factory Scheduling gives you the ability to schedule the production in your factory to a detailed level considering the capacity constraints in your environment. You have the option of three products, ranging from the simple Graphical Planning Board to the very sophisticated Advanced Scheduler; the latter being classified as an Advanced Planning and Scheduling system(APS).

SYSPRO has developed these products to utilize the strengths of the Preactor range of tools, but configured it in a way that will work elegantly and logically with the core SYSPRO modules (Work In Progress, Bill of Materials etc).

The products increase in functional richness, complexity and cost as you move up in the range:

  • The Graphical Planning Board is a fairly basic finite scheduling tool which presents your schedule graphically, but will normally require quite a bit of manual intervention by the scheduler.
  • The Advanced Scheduler on the other side of the scale is a very sophisticated scheduling system, employing advanced scheduling algorithms and considering all constraints such as tooling, material requirements etc. The Advanced Scheduler is the only tool in the range which can be considered a true APS (advanced planning and scheduling) tool. The other two products will be classified as finite scheduling tools, i.e. only the scheduling portion of APS.

These tools are all pure scheduling tools. Using these tools does not imply that you will not require other high level planning processes and tools (e.g. MPS/MRP, Rough cut capacity planning etc.) to be in place. The scheduling tool will work in conjunction with these tools to form a complete end-to-end planning and scheduling cycle.

The Facts
The Benefits of SYSPRO Factory Scheduling

  • Develop feasible production schedules considering resource availability, constraints, shift patterns etc.
  • Provide insight into the progress of specific jobs
  • Highlight jobs that will be late and allow focus on these jobs
  • Provide insight into the expected utilization of resources for managing shift patterns and scheduled maintenance accordingly
  • Provide accurate delivery dates to customers (especially in a make-to- order environment)
  • Close the loop of communication between sales people, schedulers and the production floor
  • Achieve the right balance between flexible setup and simplicity
  • Eliminate duplication of data entry/maintenance; the routing and bills of material as setup in SYSPRO WIP module is used for scheduling

SYSPRO Factory Scheduling Features

  • Select the level of product that is best suited for your business
  • Configure the solution to model your factory using simple data setup options
  • Develop simple or sophisticated scheduling and pegging rules, customized to your specific environment and requirements
  • Integrate the solution with existing shop floor systems using import/ export and communication tools provided
  • Use event script and event calendars to customize the solution to your requirements
  • Define stock code attributes (e.g. color, width etc.) to schedule and optimize the sequencing of production
  • Use the simple report writer to generate required reports
  • Publish schedule Gantt charts in HTML format to your intranet
  • Scheduling demand from sales orders and suggested jobs
  • Provide multiple manufacturing sites within a SYSPRO company
  • Enable operation from SYSPRO to be split and stored into multiple operations in SYSPRO Factory Scheduling
  • Schedule the use of tools
  • Define resource masks with associated machines

Integration with SYSPRO

  • Inventory
  • Sales Orders
  • Bill of Materials
  • Work in Progress

SYSPRO Work in Progress enables you to minimize job costs through the efficient utilization of production resources. It allows you to accurately control costs of work orders currently in progress by tracking the material, labor and resource utilization and activity of the manufacturing process, while managing the performance of the shop floor.

The Work in Progress system enables you to post material usage and labor in real time and in batch mode. It also enables variance reporting to be produced between estimated costs and actual costs of each job. Work orders may be added for stocked items (with a bill of materials) stocked items without a bill of materials or non-stocked items.

These work orders can create a bill of jobs for all relevant sub-assemblies down the Bill of Materials chain. Labor transactions can be posted through kit issues, manually or imported into the system from a data collection interface. Material allocations can be issued to a job through kit issues or manually and optionally allow for the substitution of a material allocation when performing kit issues.

The Facts
The Benefits of Work in Progress

  • Support mixed-mode manufacturing environments
  • Track and manage material and operational costs per job
  • Monitor job variances comparing actual to standard
  • Analyze efficiency and utilization of shop floor elements
  • Track production overheads, resources, and scrap
  • Schedule jobs according to the production calendar
  • Identify overloaded work centers
  • Automatically create jobs from Sales Orders, Quotations and MRP
  • Link purchase orders to jobs to expedite receiving
  • Automatically manage the production of co- and by-products

Work in Progress Features

  • Define productive unit and work center capacity
  • Define and process parent and component quantities in a unit of measure other than stocking
  • Define movement time between operations
  • Update work center information when associated cost center information changes
  • Determine standards for machines and employees
  • Optionally include non-productive time in job costs
  • Create jobs for standard or custom products
  • Issue materials and labor to jobs in kits or by item
  • Post labor at standard or actual employee rate
  • Integrate with bar code data collection systems
  • Record costs incurred on subcontracted operations
  • Receive completed items into inspection or directly into inventory
  • Easily create rework jobs
  • Optionally receive into alternate warehouse or even as alternate item
  • Create sub-jobs with automatic transfer of values to the master
  • Multi-level job query facility
  • Calculate due dates on a forward, backward, finite or manual basis
  • Supports milestone operations
  • Place jobs on hold to suspend processing
  • Reserve and track lot and serialized item
  • Recalculate expected costs
  • Archive completed jobs as XML documents

Integration with SYSPRO

  • Inventory
  • Purchase Orders
  • Sales Orders
  • Return Merchandise
  • Bill of Materials
  • Lot Traceability
  • Projects and Contracts
  • Product Configurator
  • Quotations
  • Requirements Planning
  • Factory Documentation
  • SYSPRO Factory Scheduling
  • Accounts Payable
  • Assets Register
  • Cash Book
  • General Ledger
  • Activity Based Costing

Audit trails and reporting

  • Complete audit trails of all transactions
  • Comprehensive reporting, including percentage completed, detail tracking, job status and job variances
  • Provides extensive labor analysis
  • Detailed screen query shows current job status, activity to date and expected activity
  • Work center dispatch lists
  • Non-productive time and scrap analysis
  • Work center, employee and machine efficiency analysis