Furniture production has a more complex structure compared to the past, with the use of different technical equipment and a wide variety of materials. Furniture business has not one but many phases. Companies that can produce large quantities at once need to create fast, error-free and traceable business processes. CPM ERP is enough for all this!
CPM ERP has been prepared by considering all processes and operations related to project follow-up. With its integrated structure, it adds value to the corporate integrity of your business.
The ability to monitor all project-related processes in an integrated structure is often decisive for the success and profitability of projects. It is extremely important to plan and monitor the procurement processes according to the discovery list and the stages in the project, to instantly compare the budgets and actual values, to receive all the reports needed for the project when requested, to examine the profit/loss status of the project.
Activities for customers and dealers are planned in advance. The activities are tracked. Orders and collections received from dealers are instantly processed into the system. In this way, future payments and estimated pre-approved orders can be tracked. At the same time, operations such as applications, visits, mail, fax, and reclamation made to customers or dealers are recorded in the database. During the visit, display stock control, advertising signage control and registration are also done.
It is the system connection management, where the conditions for each connection such as price list, agreed special discount, promotion, one-to-one product deliveries, non-product promotions are recreated and determined for open-ended sales methods, according to each contract made with the dealers. During order entry, each contract made by the customer is checked. The system finds the customer’s remaining receivable and the most appropriate link for this receivable figure. It is offered either as a suggestion or as a condition. Automatic selection prevents user-based incorrect price list, discount and promotion errors. It prevents overruns, price differences and refunds. It also warns constantly when a new connection is required. In addition to the controls that prevent the exit of products for the customers/dealers who are listed as undesirable by the risk unit, which transactions are risky, how much the collateral and mortgages will affect the risk, whether they have their own check-note, customer check-note, company partners’ check, and many other things such as blacklist. It allows to evaluate different risk factors.
Models, color chart fabrics, alternative color charts and fabric and cut price differences can be created by the manufacturer. During the order entry, the stock quantities of the fabrics to be used and the previous reservations are followed. If requested, automatic fabric reservation is made for the approved order. Level 1 product trees can be viewed. Product tree can be selected according to single color or multi color (2 colors, 3 colors, 3 colors + Leather etc.). Conditions for delivery are created (group order), risk and connection control is performed for each line of the order. For standard products, unit production hours are determined and the estimated delivery date is determined by looking at the internal production. At the same time, the production status of the customer or all orders can be monitored instantly.
Orders of special designs drawn by the architect or brought by the customer are followed and technical drawings of the product can be added. Planning and production approval flow is created for the relevant concept or custom product. After the price study and approval, the order created for the concept product, whose product tree is prepared, can be transferred to the product tree automatically. For the products whose models are drawn and designed by the manufacturer, the special fabric selected with the pre-upholstery (Skeleton) price, and the SPECIAL productions transformed into a customer-specific product and price for the accessories to be used are followed.
Upholstered group production planning charts are created as graphics or documents by checking the products, pending orders, personnel and equipment on the production line.
Integration can be made with software specially designed for plot planning and drawing programs used in model design. Get information about which programs. (Appropriate database integration requirements must be met.)
Taking into account the orders with production orders and orders that have not yet been ordered, stock status, reservations, products that have been ordered but not yet arrived at the warehouse, min/max stock and lot sizes are determined as needs. Action plans are created and purchase request, order, deadline or in bulk.
By communicating with the quality control machines, the quantity controls are made in the fabric quality control machines by separating the fabrics taken as meters into lots and rolls. Lot-based fabric rolls with approval or conditional approval are taken to the finished goods warehouse, and fabric rolls that fail the scoring system are returned to the rejection warehouse. In addition to all these processes, laboratory tests are also recorded if they are to be applied thanks to the module.
A purchase order is created for the purchase offers that are decided to be purchased. All information about the material received in the purchase order, payment terms, delivery date and all details of the place are entered into the order. The purchase order is sent for the approval of the finance department first, then the project manager, and then the General Manager depending on the amount of the order. Approvals can be made directly through the program or on the Web.
The shipment planning of the materials to be shipped to the construction sites is made according to the delivery date entered in the purchase orders.
In order-based production orders, station and module-based consecutive barcode numbers of the upholstered group product are monitored at every stage of production. Start and finish, stops (planned – unplanned), errors, shifts, production stations and units are tracked.
In the upholstered group, the number of modules produced per day, the production hour performance percentages and the performance on the basis of the product produced are monitored on an instant, daily, weekly and monthly basis. Thanks to the barcode numbers that follow each other, it is possible to monitor which employee made which part of which product, in how long, at which workbench or station.
The estimated cost (preliminary cost) for the model and modules is compared with the actual cost. Costs can be calculated on the basis of work centers, routes or processes. Additional costs distribution key or company-specific distribution management can also be used.
Orders whose production is completed or about to be completed are planned according to the delivery dates, taking into account the routes. According to the shipping method, the weight, M2, M3 analysis determined for each product is made and the correct loading vehicle is suggested. In this way, freight costs are minimized with correct planning and shipment.
According to the created shipment plans, the team integrity of the order items that have been completed and arrived at the finished warehouse is maintained and controlled. Barcode is read and output is provided without any missing parts. The necessary conditions for exit can be designed specifically for the company. Products that have not been loaded are revised in the shipment planning module to be rescheduled. Instantly planned actual shipments are tracked.
Special or mass production orders are created according to details such as coating color, accessories, lacquer in the orders created for the module or the set. Special conditions are created from the products to be shipped together to the special issues during the shipment. During order entry, stock control is performed on a package basis according to the available stocks. If requested, the products that will consist of packages can be shipped from stock by taking into account the common packages and assembling them.
Taking into account the delivery times, many variables such as min/max stocks and goods to come from the road, min/max purchase lot sizes and current package stocks are taken into account and the actual material requirement is determined. The resulting material requirement plans are converted into material demand on the basis of work orders, according to deadlines or in bulk.
In case of instant customer demand changes, the material requirement planning calculation process, which takes hours, is left behind! Decision-making processes are shortened with the needs optimization system created according to modular production conditions.
The products to be produced for each order or stock are converted into a production order in bulk. During production order conversion, stack barcodes, package barcodes, and assembly instructions are printed. Data such as raw materials and auxiliary materials to be used during production, from which warehouses they will be taken and instructions to be used during production are created.
It is determined in which work center, production lines and machines the planned production orders will be produced. Ongoing works in the production area are planned according to the unit production times of the jobs. It is the system in which the production end times and loadings, bottlenecks, the most suitable route and machines are determined and planned, and the realizations are followed at the same time.
Document productions created on the basis of orders are loaded on the machines on a stack basis for mass cutting. The products that go into production in bulk until the packaging stage are now tracked on a stack basis. If requested, work orders are loaded or read on machines (M2M) by exchanging data with Machine-To-Machine connection management.
Thanks to touch screens at every stage of production, work centers, resources, routes, production numbers on the basis of processes, shifts, personnel, errors, planned or unplanned stops are monitored at the same time. After the completion of each production stage, consumptions and formed semi-finished product stocks are created with a barcode system independent of the user.
Thanks to the barcode and touch screen production tracking system, the starting, ending and set-up times of the working personnel are tracked. Lost times such as shift changes, stops, stack changes, loading can be analyzed and thus employee performance analysis reports can be prepared.
With the inventory tracking system on a package basis, products that can be created from existing package stocks and missing packages are determined at any time, and modules can be created from stocks. Optimum product creation and common package requirements are determined for common packages.
Storage methods such as warehouses, shelves, compartments and rows, which are the requirements of a package-based stock management system, are used for products that have been shipped. It is a dynamic warehouse management system created to reach information such as where the package stocks of different sizes are in the warehouse layout plan and from which shelves they will be collected during loading.
The montage instructions for each product are attached to the bill of materials or package stock semi-products as pictures and instructions. During the creation of the work order, montage instructions are distributed along with the stack. Likewise, with the packaging tracking system, data such as which packaging materials will be used in which package, which parts will be in the packages, which accessories will be placed in the packages are followed. Consumption is also made during package formation.
The shipment plans created by the sales coordination departments according to the delivery locations and customers are forwarded to the logistics unit. The logistics unit distributes the number of packages of the modules to be loaded, and on which shelf and in which row these packages are, to the collection team with a list created from the planning module. The team collects the relevant packages in the shipping area. The shipment is carried out by checking the missing package with barcode shipment.
An invoice is issued for upholstered group beds, bases and modular group products and the invoice is accounted online, for which a waybill is issued by the logistics department. After all transactions such as packing list, export invoice, Turkish and English invoice, loading notes and ATR documents for export goods are completed, the records are accounted together with the customs costs incurred and profitability can be reported on export basis.
Incoming service requests and required repair and maintenance operations (guaranteed, out of warranty) are tracked on the system. With the analysis reports of the causes of failure (customer-sourced, production-sourced, assembly-sourced, etc.), the data needed to take preventive measures in the enterprise can be accessed instantly.