Eliminating Miss-Shipments with Hyper-Tight Process Control™
Bergin Fruit and Nut uses Deacom ERP with native WMS to ensure they consistently adhere to rigorous quality control standards as their customer demands shift. With Hyper Tight Process Control™, the food manufacturer has been able to ensure that critical process steps are always followed.
Implementing Hyper-Tight Process Control™
- Educate your Supply Chain Management staff about the value of strong quality control and how it impacts the “cost of being wrong“ with the 1-10-100 Rule.
- Determine and document which elements of your supply chain are quality-critical (Procurement, Quality Control, Receiving, Production, Shipping, Document Generation).
- Define the process checkpoints and quality data specifications/formulas on an item/recipe/customer level.
- Define escalation procedures when a process stop is indicated.
- Make sure all affected ERP components (Procurement, Quality Control, Receiving, Production, Shipping, Document Generation) are ideally in one system and work seamlessly with each other.
- Test and refine the system.
Cost of being wrong about demand planning:
From a forecast demand to a sales order demand or safety stock associated with min/max, companies need to ensure the inventory levels they are maintaining can meet those demands. If Materials Requirements Planning (MRP) and scheduling are done outside of the main ERP system, there is a good chance that the right materials are not being purchased at the right time.
There are also cases where inventory levels are too low which can push out production runs because inventory is not available and ultimately delays shipment dates to customers. On the other hand, there may be times when a higher-than-normal level of on-hand inventory is being maintained. This can tie up cash flow, take up valuable space in the warehouse, or even make companies think they need to rent more space when it may not be necessary at all.
By having all the functionality associated with MRP and demand scheduling, Deacom ERP provides you with the information to make the right decisions on what to purchase and when to purchase so your inventory levels meet your demands.
Advantages of a Hyper-Tight Process Control™
Hyper-Tight Process Control™ is interwoven throughout Deacom ERP’s planning, procurement, receiving, production, quality, shipping, and document generation functionality, allowing real-time access and management of the formulation to shipment process.
With Hyper-Tight Process Control™ businesses can create scalable and repeatable business practices to deliver continuous high-quality products, eliminating the “cost of being wrong,” preventing potential legal claims, recalls, low customer satisfaction, and the deletion from preferred supplier lists.
By implementing process stops that cannot be bypassed throughout the product lifecycle, manufacturers can detect quality issues early so resolutions can be made with minimal expenses. These checkpoints also help companies grow their businesses without increasing process complexity or adding resources for quality control in order to secure full quality compliance.
Ensuring Hyper-Tight Process Control™ Requires:
ERP core functionalities, procurement, warehouse, production, shipping, document generation, process, and quality control should be native to one solution. If any of these components are done in a separate system, manually, or outside of Excel, then critical steps can be easily bypassed or done incorrectly, causing breaks in process control.
Quality control procedures and measures
Quality control procedures and measures can be defined at the parts and formulation level within the core ERP.
Configurable quality checkpoints
Quality checkpoints can be placed at any stage to meet the unique needs of the business.
Prevention of Checkpoint bypasses
If quality measures are not met at process quality checkpoints, the system must stop executing the process, even if previous ones have been skipped.