Process industry
Process industry

ERP for the process industry – integrated standard system with industry functions

The ERP software for the specialized requirements of the process industry

Growing requirements for flexibility and supplier capabilities, increasing cost pressures, global supply chains, and constantly changing regulations: Powerful ERP solutions from ORDAT support companies from the process industry in remaining competitive, even under the most difficult conditions.

Having completed numerous successful projects for the process industry – for instance with customers from the chemicals industry, rubber processing, the paint/varnish area, the pharmaceuticals industry, the porcelain industry, or the food and drink industry – ORDAT understands the challenges of the sector in detail. Even standard solutions from ORDAT offer numerous customized functions for process manufacturers, including recipes, free input-output formulas, joint production with varying yield ratios, and reclamation, batch tracking, or support for heterogeneous production structures.

Our solutions help you:

  • your plan and control your processes in an integrated way
  • to use your production and staffing capacities in the most optimal manner possible
  • Lowering costs for manufacturing and logistics
  • Reducing processing times
  • Maintaining absolute adherence to deadlines
  • Fulfilling compliance requirements

With ERP solutions from ORDAT, process manufacturers can effectively control all of the variables along their supply and manufacturing chains, communicate more efficiently with suppliers and customers, and use their production and supply capacities in the most optimal manner possible.

Consistent integration of all operational areas – from manufacturing, logistics, and materials management to bookkeeping and cost accounting – ensures transparency, guarantees data is always up to date, and reduces maintenance work for your system.

Improve competitive position

ERP solutions from ORDAT can help you be more competitive – produce even more efficiently and less expensively, deliver products to your customers even more flexibly and more reliably, and control your processes in an even more forward-thinking manner. Powerful planning functions ensure you use materials more efficiently, utilize your capacities more wisely, shorten your lead times, and optimize your inventory levels. Consistent control of the flow of information across your entire supply and delivery chains ensures maximum transparency. This allows you to identify cost drivers early on, shorten development cycles, and react more quickly to market trends.

Map complex and heterogeneous production processes

Many process manufacturers use heterogeneous production structures, which may consist of a combination of process and individual manufacturing. ERP solutions from ORDAT map even complex discrete manufacturing processes in a consistent way, supporting all types of manufacturing from series production to individual manufacturing, prototyping, and small series. Production planning and controlling is flexible, and is based on bills of materials administered in parallel, as well as recipes and work schedules.

Ensure compliance

Whether they are coming from the chemicals, food, or pharmaceuticals industries, many process manufacturers must seamlessly observe countless national and international regulations, which may change at any time. ORDAT solutions offer numerous powerful functions for quality and compliance management, including sophisticated batch administration to ensure the traceability of materials on their journeys from suppliers to consumers (traceability), and support for documentation requirements, for instance by mapping chemical, physical, and technical data as needed.

What our clients say

“ORDAT 100 percent fulfills all of the criteria we set out for it. The FOSS recovery function completely covers the material management requirements for our sorting insert manufacturing system.”

Erhard Lindner, Production Manager, Kaupert GmbH 

More References

    Specialized ERP functions for the process industry

    Input / output calculations

    Your ORDAT solution allows you to create freely definable formulas for calculating input / output structures, such as from the quantities and processing times required for a product. Using these formulas, you can reliably achieve the desired target quality, even with raw materials of varying quality. Libraries with data on all desired materials characteristics can be constructed, as the basis for these formulas.

    • Determination of process and work schedules
    • Determination of component quantities
    • Integration of all desired material characteristics

    Variant manufacturing

    Supplier capabilities must be ensured under all circumstances, even in the face of an increasing diversity of variants. Variant controlling from ORDAT offers a powerful set of instruments for administering a product and all of its features and forms in a single recipe / bill of materials. This allows users to significantly reduce the number of recipes and bills of materials they need, as well as the numbers of process and work schedules.

    • Well thought-out variant administration
    • Variant capabilities for both bills of materials and work schedules
    • Almost unlimited number of forms can be defined
    • Consideration of formulas
    • All desired calculations of quantities used and work scheduling times, depending on variants

    Quality assurance and management

    ORDAT solutions offer multiple powerful functions for quality assurance (QA) – from supplier evaluations to real-time process monitoring and convenient administration for complaints and returns. Automatically assigned quality status levels for all goods received help to assess the quality of inventory, for instance to regulate material releases or block operating orders. The solution maps any requested chemical, physical, and technical data, making it easier to precisely document batches and qualities.
    ORDAT supports all key instruments, standards, and processes used in quality management (QM), such as ISO 9000, ISO/TS 16949, and Advanced Product Quality Planning (APQP). In addition, the open system architecture allows the solution to integrate easily with all QM systems available on the market.

    • Administration of freely selectable QA data, by item or by series / batch
    • Quality status for inventory quality assessments
    • Quality inspections in goods receiving, with goods assigned to a certain warehouse location based on quality level (general, skip lot sampling, or part-dependent)
    • Return shipment processing and complaint information in purchasing, or return processing in sales
    • Generating inspection and QA orders
    • Free formulas for defined target quality
    • Meaningful target / actual comparisons
    • Generating certificates and QA documents

    Recovery percentages

    To provide reliable calculations and update inventory correctly, recovery percentages for materials must be taken into consideration. Your ORDAT solution reliably determines material quantities and values from recovery procedures, removing the appropriate amounts for operating orders as needed.

    • Store a set recovery percentage for the components
    • Determine a concrete recovery quantity

    Traceability

    Consistent series and batch-based inventory management allows you to efficiently manage your deliveries to manufacturers and system suppliers – and thanks to seamless tracing for series and batches, you can successfully defend against unwarranted liability claims.

    • Article-based series / batch structure
    • Where-used list (product liability)
    • Delivery batches designated on external shipping documents
    • Seamless traceability for semi-finished products and raw materials requiring batch handling, all the way to the suppliers
    • Reliable tracing for batches associated with complaints through warehouse locations and production levels to the customer

    Management of recipes, bills of materials, and formulas

    Your ORDAT solution manages recipes and bills of materials in parallel. You are not restricted to using fixed quantities for your recipes, as in bills of materials, but can also work based on percentages. By storing freely definable formulas – for instance, to determine process and work schedules or quantities of components used – you can reliably ensure you achieve a desired level of quality, even when using raw materials of varying quality.

    • Management of recipe components by quantity, weight, or percentage
    • Conversion of percentages into quantity units for inventory management and net requirements calculations
    • Management of exact relationships between mixers, compounds, and fill weight
    • Freely definable formulas, for instance for process times or quantities used, based on libraries of selected chemical, physical, and technical properties
    • Consumption simulation for complete containers and percentages

    Joint production and recovery

    ERP solutions from ORDAT support simultaneous manufacturing for multiple parts, each with their own production order (joint production) – with both fixed yield ratios and ratios varying within set limits. Joint products can be managed in a flexible manner. When alternative components are used, the new yield percentages are calculated easily based on saved formulas. in addition, joint products are taken into account in the percentage of reclaimed materials in calculation and materials planning.

    • Joint production with multipurpose tools
    • Fixed and variable yield ratios
    • Recovery percentages taken into account in calculations and materials planning

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