Solutions for Production Management of Sanying Aluminum Sheet and Strip

Sanying Aluminum is a Sino-Australian joint venture engaged in research and development of aluminum sheet, strip and foil, production of aluminum processing modern enterprises. The company put into operation in 2004, and has formed an annual production capacity of 80,000 tons. It has outstanding technological research and development capabilities. It has set up a technical team composed of more than 30 senior technicians in the domestic aluminum processing industry, which has been recognized by the national high-tech enterprises. Aluminum sheet, aluminium coil strip, aluminium curtain wallboard, single-zero aluminium foil and other products are widely used in packaging, machinery, household appliances, building decoration, automotive accessories and other fields.

In recent years, enterprises in the aluminium industry are facing fierce market competition and the increasing cost of raw materials. In the production management of aluminium materials, there are some problems, such as misallocation of resources, reduction of product yield, and inconsistency of staffing. Sanying Aluminum faces the same problem, but the company soon finds out the problem and tries to find the right way to solve it. Under the leadership, the company and Haotai Science and Technology Co-operation, after more than a year of research and development, finally developed a set of ERP system to adapt to the development of the aluminum industry - "Aluminum Plate Expert", to solve the problems arising in the company's production management, starting from the process efficiency management, so as to make the production more smooth and effectively control the finished aluminum products. Cost. To improve the efficiency of production management, ERP system starts with the following characteristics.

1. Sales Department

Key Information: Sales Supervisors need to monitor the weight of orders placed on a daily basis. Sales managers and documentaries need to monitor whether the warehouse has suitable spare materials or surplus materials before placing orders. After placing the order, follow up the production progress of their customers'orders. After delivery, we need to follow up the customer's repayment.

On-site effect: Sales Supervisor checks relevant information through "statistics of order entering and leaving warehouse". Sales managers and merchandise orders pass the "Order Status Table", "Volume Number Tracking Card" and "Account Age Analysis of Receivables".

Value-added benefits: Real-time understanding of current orders, better grasp the sales plan. Quick and accurate order, reduce the waste of time and improve efficiency. The on-site report can delay the information between the sales manager and the customer, for example, it can provide delivery time more accurately.

2. Production Planning Department

Key information: The head of planning department needs to monitor the production of casting and rolling billets for each alloy every day. Receive the current stock of billet, surplus material, problem material, spare material and so on. The quantity of unfilled sales orders, the quantity in production, and the production tasks of each machine. Concern about the daily warehousing volume and sales volume of finished products. How to accurately feed and track.

Field effect: The director of planning department checks the relevant information through the Billet Stock Statistics Table. Through the corresponding warehouses to check the inventory of materials, which is divided into "factory materials" and "customer materials". Through the "order status table" to see the amount of unfinished materials, "in-process statistics" to see in the production, each process "production guide" to see the amount of production tasks. Check the daily storage volume and outgoing volume through the "statistics of inbound and outbound orders". Feeding and tracking.

Value-added benefits: Reduce the cumbersome of EXCEL inventory summary and re-statistics, greatly improve the efficiency of production order. Workflow production scheduling mode can pre-arrange production tasks in advance, eliminating the trouble of collecting and redistributing work cards in the workshop of the planning department. Now the planning department cancels the evening shift directly and reduces the expenditure of two employees. The production process route of the product has been completely retained, and the worry about the flow of key employees in production has been reduced. By setting the optimal feeding scheme, the optimal production order and feeding arrangement can be filtered out.

3. Solution of production report (cold rolling workshop, annealing workshop, finishing workshop)

Key information: Know your own workshop production tasks. The production information of the previous process, such as the position of incoming material, the specifications of incoming material, the situation of incoming material and so on. Easy to input.

Field effect: Simplified input, are directly input by machine personnel, about each volume of a process input only half a minute. Look at the production guide without waiting for the production planning department to send the task list.

Value-added benefits: Reduce the production workers'spare waiting time, because workflow production mode automatically generates production tasks of next process. Workshop teams can timely check their daily production volume, link with wages, stimulate employees' dynamic workflow production mode, and supervise the production of the next process. Function, if the previous process is wrong, the next process is put forward immediately, because the output of each department is linked to performance, which can better clarify the responsibility. Information sharing, on-site job reporting accurately reflects to each user of the software, external can provide customers with current production schedule information on time and effectively, and facilitate the effective control of planned production. There is no need to increase the number of staff, the machine staff can directly complete, there is no misunderstanding that additional staff can complete the real-time report.

4. Quality Inspection Department
Key information: Intercept problems in time. Can put forward the treatment plan in different levels.

Field effect: If there is a problem, it is intercepted by the quality inspector and submitted to the head of the quality inspection team for treatment advice. Then it is re-scheduled by the production planning department. For each customer to establish a quality file, can quickly give treatment advice.

Value-added benefits: timely interception, the problem can be immediately reflected to the supervisor, without delaying production progress. Opinions at all levels need not be transmitted on paper or by telephone, and the information is more complete.

5. Warehouse Management of Billet, Residual Material, Raw Material and Finished Product
Key Information: Inventory Occupancy of Products with Different Attribute Quantities in Various Warehouses Field effect: For example, what quality problems were recorded in the problem warehouse, billet inventory, casting and rolling mill number information, and finished product warehouse, packaging and packaging information were recorded.

6. Receivable Management and Payable Management
Problems encountered: Leadership is very cooperative, but employees do not. Special function development. Solution: Linking with performance, calculating employee's wage through report forms can effectively solve the problem of real-time job reporting, such as calculating daily production wage of cold rolling process through "cold rolling yield". Software is our company's sheet and foil rolling production industry software, embracing the right of independent research and development can perfectly support secondary development. For example, Phase II of Sanying Plan, Cold Rolling Standard Man-hour, Production Cost, Wage System, Order Temporary Estimation Profit System...

ERP flow chart for aluminium sheet production

The biggest effect that ERP brings to the operation of the factory is the rapid sharing of information, query, and can optimize the control flow to achieve the orderly operation of the factory; of course, there are different needs for each level. ERP system has become an indispensable platform for daily production management, but there are still some deeper problems to be solved. Only by effectively resolving these problems and scientifically implementing the control of production cost, can enterprises effectively expand their living space, change backward production management mode and keep them prosperous. Vitality is in an invincible position.