SAP ERP Solution for High Tech Electronics Industry

A sales forecast management component tailored for the electronic manufacturing industry, utilizing accurate data support to make reasonable production and capacity predictions, timely procurement and material preparation through the system, and develop reasonable production plans.

• Flexible sales forecasting methods

The plan can develop multiple flexible sales forecast plans based on different departments, salespeople, sales channels, regions, countries, workshops, warehouses, and products, and users can fully determine the rough or fine level of forecast formulation based on actual needs.

• Provide two solutions

The same solution provides MRP and LRP functions to solve the problems of predicting production and receiving orders. MRP can consider sales forecasts, received orders, issued purchase orders, alternative materials, safety stock, semi-finished product inventory, losses, and other situations to provide material preparation suggestions in advance to purchase materials with long lead times; After receiving the order, perform LRP calculations based on the order to develop production plans and procurement plans for short lead materials.

Regardless of whether it is in the assembly line production of components, or in the assembly and processing production of orders and inventory oriented production, any production mode in the electronics industry can be flexibly applied.

• hree levels of planning

The plan provides three levels of planning and control: Master Production Plan (MPS), Material Requirement Plan (MRP), and Rough Capacity Plan (RCCP). Through flexible parameter settings, it effectively solves the problems encountered in workshop production planning and material procurement.

• Automation of production planning

Based on MRP related information, such as BOM (Product Material List), loss rate, substitute materials, material expiration date in BOM, procurement lead time, inspection time, minimum purchase quantity, packaging quantity, etc., taking into account demand information (orders, sales forecasts, etc.) and supply information (unclosed purchase orders, unfinished work orders, etc.), production and procurement plans are automatically generated. At the same time, they can be set by users, Mark urgent procurement or production documents for special handling by management units. In addition, it provides BOM version management function to facilitate cost accounting and production material issuance.

• Configurable flexible BOM

Due to the diversity of products in the electronics industry and the speed of upgrades, BOM has high uncertainty. The solution provides configurable BOM, which is suitable for various complex BOM applications, maintenance, and management.

The plan has a complete quality management and traceability process, with serial number and batch tracking management comprehensively running through various business nodes such as raw material procurement, in transit, production, warehousing, and outbound of orders. It can trace every step of the product, making the quality of the product visible and transparent.

• Serial number and batch tracking management

The solution provides the serial number management function and batch tracking function required for product traceability, and combines sales and service modules to manage the after-sales service of products, solving the urgent needs of electronic product manufacturers for after-sales service and combating counterfeit products.

• Full business process traceability

The serial number and batch number are labeled with barcodes throughout the entire business chain of electronic products from raw material procurement to finished products. Barcodes are used to record quality inspection results, and the system can trace the results at any time, improving work efficiency.

• Reverse traceability

For products sold out, in maintenance management, the solution provides serial number management. When there is a problem with a product, the maintenance status can be recorded in detail, and the original production status and raw materials of the product can be tracked. In turn, the same batch of products of the product can be found, as well as the sales or inventory status of these products.

The plan has built an intelligent warehousing system, which achieves refined inventory management through docking with equipment such as PDAs, barcode guns, inventory machines, and various transportation equipment, thereby optimizing the procurement process and improving inventory accuracy.

• Innovative integration of barcode labels and RFID technology

Intelligent devices run through the entire logistics process, achieving data-driven and intelligent control of products.

• Establish application scenarios for automated equipment such as three-dimensional shelves/containers

By using information technologies such as the parent vehicle system, four-way shuttle vehicle technology, multi-layer shuttle vehicle technology, ground four-way light 2 heavy AGV technology, cargo to person picking system, WMS (warehouse management system) system, WCS (warehouse control system) system, etc., the solution of "shelf+robot=automated warehouse material storage system" is achieved.

The plan helps electronic enterprises reduce stagnant materials in four stages: research and development, planning, execution, and post analysis.

• Research and development phase

Remind in advance of possible dullness. When product design changes occur, a list of expected dead materials will be generated for materials that are expected to fail; On the other hand, inventory materials that have not been used in all BOMs will be identified for management to determine if they are sluggish.

• Planning phase

The system provides MRP/LRP with the aim of meeting production plans with the minimum amount of materials and the shortest occupied time.

• Execution phase

The system provides the function of querying alternative materials, which makes it convenient to query the situation of alternative materials when there is not enough raw materials available.

• Post event analysis

The system also provides various reports in inventory management to indicate materials that have already become obsolete, such as material estimated status table, obsolete material table, material batch number and period control table, etc. If the customer cancels or changes the order, it can also be tracked based on the order procurement status provided by the system to quickly identify the corresponding purchase order, facilitating procurement personnel to take measures.

The plan clearly covers the expenses incurred in all processes of electronic manufacturing enterprises, from sales to research and development, from procurement to production, from warehousing to outbound, and effectively monitors business processes. It helps electronic enterprises obtain refined cost information, effectively saves and controls operating costs, and applies more funds to product research and development and expansion of operations.

• Cost refinement division

The plan divides costs into: material costs, labor costs, manufacturing costs, and processing costs. The cost calculation method is flexibly configured according to requirements to adapt to various complex cost accounting situations, and has clear data reports for various expenses incurred in various business processes, freeing financial personnel from complex manual tasks such as data collection and cost allocation, providing cost information to managers faster and more accurately, and improving the management decision-making level of enterprises.

• Flexible report visualization

With the flexible data reporting and business analysis suite of SAP ERP, enterprises can visualize production cost data, effectively control cost analysis and gross profit analysis, and obtain real-time input and output of each task.

The plan constructs MES workshop execution function on the basis of SAP, meeting the needs of electronic manufacturing enterprises in the production execution process to solve the problems of delayed order execution, scattered processes, rough production capacity, and low efficiency, in order to improve the efficiency of workshop operations.

• Strengthen workshop operation plan

Reasonably allocate personnel and working hours, provide timely and accurate production feedback, ensure the transparency of production data and progress, and improve the completion rate of production plans and product delivery times.

• Real time collection of workshop data

By using barcode technology to track the entire production process from material production to finished product warehousing, all events that occur during the production process are collected in real-time, making the entire workshop completely transparent.

• Transparent production process

Make the product clear and transparent throughout the entire production process, efficiently trace the causes of problems, develop targeted measures to solve quality bottlenecks, achieve product quality traceability, and reduce costs.

• Progress and resource tracking

Real time recording and monitoring of the completion of production processes and processing tasks, analyzing personnel work efficiency, labor productivity, equipment utilization, product qualification rate, scrap rate, etc., promptly identifying and improving problems during the execution process.

Combining SAP's research and business practices at the Industry 4.0 level for intelligent manufacturing and smart workshops, TransInfo R&D Center is based on the SAP system, targeting small and medium-sized manufacturing enterprises. With affordable costs, it helps small and medium-sized manufacturing enterprises build light intelligent manufacturing application scenarios, and leverages SAP Leonardo's innovative solutions to bridge multiple automation devices and data centers.

• SAP Solutions for Industrial Internet

Omni Channel Solutions（Hybris）/Core Operations Management（S/4 HANA ERP）/Agile R&D Management（PLM）/Intelligent Manufacturing Solutions（ME/MII）.

• SAP solutions for external IoT:

SAP HANA Cloud Platform/Big Data Predictive Analysis/SAP Leonardo IoT Solution.

The combination of SAP Leonardo and related intelligent manufacturing hardware equipment: Siemens/Panasonic/Foxconn/Honeywell, etc.

When the R&D personnel have completed the establishment of the product BOM structure, and all stages of semi-finished products and raw material related products have been reviewed, the plan provides functions for material change and replacement during the testing phase when the product needs to adjust the material ratio, change suppliers, or modify the production process (process) due to fluctuations in raw material prices. At the same time, real-time updates are provided for sales quotations.

• Flexible change of BOM materials

Provided relevant functions for the ECN Design Change (BOM Change) module, which can make material changes to the BOM table (including material replacement, addition, deletion, or changes in material usage and loss), as well as material supplier changes, route changes, etc. At the same time, record the BOM version number for future tracking and querying.

• Improve front-end work efficiency

When the BOM material changes, the sales configuration plan corresponding to this BOM will be automatically updated. The BOM will be synchronized with the configuration plan, which can help enterprises reduce the workload of repeatedly entering configuration plans, improve efficiency, and optimize configuration.