ERP Software for the Chemical Sector

ERP Software for the Chemical Sector

Basic chemical products are the foundation of fine and specialized chemical production, which, in turn, represent the basis of many different industries. The chemical industry is an extremely dynamic sector globally, and for that reason it is undergoing many significant changes.

The chemical sector represents one of the most important industry sectors of the global economy.

SAM ERP2 is a cutting-edge ERP system designed and developed specifically to fit the needs of companies working in this sector.

Its functions allow companies to manage not only administrative and commercial processes, but also the needs that arise from the purchasing of raw materials, their storage and transformation, quality control processes, and lastly the tracking and traceability of goods, all in the best way possible and in full compliance with current regulations and with the requirements of the company.

Our software is accurate, secure, reliable, and easy to use. These are just some of the characteristics that make SAM ERP2 a perfectly adaptable product for every commercial and productive businesses operating in the chemical sector, whether large or small.

SAM ERP2 is a powerful, cutting-edge ERP system developed by Centro Software for full and integrated management of companies operating in the chemical sector. Management of processes can be configured to fit regulations and procedures for even the strictest quality certifications. SAM ERP2 includes management of advanced logistics and is supported by INDICOD standards “UCC/EAN-128” and “SSCC”, which represent essential tools for certifying the quality of company processes and products along the entire production chain. SAM ERP2 allows companies to monitor processes, optimize workflows and reach high levels of competitiveness by providing them with the tools to define workflows, implement management control systems, calculate contribution margins, and produce advanced statistics.

RECEIPT OF ORDERS

SAM ERP2 allows to perfectly synchronize demand and product availability. Thanks to EDI tools and operational web portals, it is possible to collect orders and forecasts in a lean and efficient way. The “sale forecast plan” allows to schedule supply processes (purchase or production of finished or semifinished products) separately or in conjunction with the collection of orders, even without actual orders and in a way designed to arrange delivery programs and open orders.

“Closed cycle” MRP PROCESSING AND MRPII (FINITE CAPACITY SCHEDULING – FCS)

The MRP module allows to assign tasks to company resources by also predicting delivery dates and product availability, not only based on orders plan (MRP-I), but also by taking into account the company’s productive capacity.

The ERP system takes into consideration machines, plants, schedules, priorities and correlations between processing phases, production cells, departments, cost centers.

Immediate and full control over production is provided by dispatch lists (work sequences on each production resource), analysis of queues, and Gantt diagrams for each P.O., on which it is possible to intervene graphically to change the scheduling, and to process and save scheduling plans.

PRODUCTION ORDERS AND MES

SAM ERP2 offers full control over the entire operating production process, both for internal and external activities. It allows to manage production orders, picking lists and processing cards, check on shipping availability (by lot characteristics, purity, quality details, clients’ tenders), progress of work phases,

management of isolation and approval areas, measurement of production time, management of contract work and external processings, immediate control and registration of processings, both completed and in progress (Work In Progress), and lastly assignments and availability of materials. The MES system provides real-time control of the status and the usage of resources (machines, plants, staff) through the synoptical panel, while also allowing to collect production time data through barcodes, monitor staff attendance for the final count of working hours, produce graphs for checking the performance of resources, and finally carry out maintenance on machines and plants.

MANAGEMENT OF WAREHOUSES AND LOGISTICS (“UNDER ANALYSIS”, “APPROVED” OR “REJECTED” PRODUCTS)

SAM ERP2 allows to assign technical and management data (lot status, purity, dates, certificates, etc.) to each lot or Loading Unit, which is essential to transfer and move goods in a controlled and consistent way to guarantee efficient control plans. Thanks to the integration with the “Wireless Advanced Logistics” it is possible to recognize and transfer goods by reading their barcodes and validating them in real time from the central system: receipt of goods, shipping, picking, transfers, inventory, sampling check and plans, management of locations (Aisles/Levels/Columns), “loading units”, as well as optimization of spaces, dynamic mapping of warehouses, etc.

COST ACCOUNTING and MANAGEMENT CONTROL SYSTEM

The functions of SAM ERP2 also include a detailed distribution of costs and revenues by destination. This function has two main purposes: accounting by sale order (which produces cost accounting budget by area, agents, items, etc. while also calculating profitability margins) and accounting by cost centers, which includes the costs divided by department and allows to calculate costs by units (gross cost of staff or plants). Accounting by business areas (or departments) also allows to obtain sectorial budgets by branch, production line, company departments, break-even points, etc.
Thanks to the Business Intelligence System and the Data Mining tools it is also possible to automatically process summary information for monitoring and managing your business by generating immediate diagrams and graphs to make it easier to analyze and interpret data. The results of such processings are essential for making the best operational and strategic decision in every different area.

MAINTENANCE OF PRODUCTION PLANTS – INDUSTRY 4.0

The concept of Business Continuity, namely the ability of continuing to provide products or services with no interruptions, is of fundamental importance in this sector, as it requires certain production and delivery times while also incurring in issues such as the perishability of goods.

Predictive and preventive maintenance jobs on production plants can reduce the risk rating related to such issues. CMMS (Computerized Maintenance Management System) allows to manage the maintenance of company’s plants and equipment by suggesting “review”, “replacement” or “repair” interventions before functioning anomalies can even occur. This allows to plan “plant downtime” in advance to carry out maintenance interventions at the most appropriate time, thereby optimizing the working time of the plants in full compliance with the WCM regulations (World Class Manufacturing).

The CMMS Module is fully integrated with SAM ERP2 and the entire workflow is automatic: when the limits set are exceeded, the system proposes or issues a MO (Maintenance Order) which includes the Bill of Materials which, in turn, contains the information that maintenance workers need to pick up replacements and carry out maintenance work (replacement code, lubricant type, estimated time, pictures or links to web pages, technical specifications, etc.). It is essential that this function be connected with digital devices that allow the software to communicate in real-time with the ERP system and the production plants

(e.g. electronic card “Black Box C4” designed by Centro Software). The implementation of such technologies represents the first step to access Industry 4.0 and have the benefit of super-depreciations.

TOOLS FOR CONTROL, SECURITY AND WORKFLOW MANAGEMENT

SAM ERP2 offers all the necessary functions for fitting the needs of the chemical sector and, in particular, to validate all processes to comply with the specific regulations:

  • Management of passwords – Password uniqueness, minimum length, scheduled expiration, repetitiveness restrictions, ability to freeze a user after “n” access attempts.
  • User Login Timeout – Ability to configure each session by limiting the maximum time each operator can be logged in for.
  • Controlled Access – Ability to configure security parameters to give each user limited access to applications, plant areas, security areas and data.
  • Security System – The system administrator can set limits for each user or group on the single form fields or on the toolbar, thus defining which users can enter, view, or modify the data field by field. It is also possible customize labels for each form by setting their language or description according to the user (it is possible to create groups by role, e.g. “Technical Analyst”, “Operators”, etc. All users associated with these roles automatically inherit rules and limitation of the group and can only use enabled functions). Security System also allows to manage document signature with chain approval (with no need to print documents).
  • Digital Signature – Electronic signature is based on different cryptography methods. Regulations require that “signed electronic records” contain other relevant information such as the name of the person signing, date, time and function of signature (review, approval, assumption of responsibility, etc.). Electronic and manual signatures must be associated with the corresponding electronic records to ensure that the signature cannot be copied or transferred in an illegal or counterfeit way.
  • Workflow, Tracking and Audit Trails – The WFDC system (Work-Flow Design & Control) makes sure that the data are entered correctly and in accordance with corporate rules, which merge with the program standard rules, thereby managing company workflows by validating each single step of the process. The Audit Trail integrated system allows to verify by which user each piece of information has been entered: username, date and time, function used, previous value and entered value, software function or tool used. The “TAC” control system (Tracking & Auditing Control), besides monitoring the activities carried out on the database, can also generate automatic messages and send them to pre-set email addresses whenever certain conditions occur or when certain operations are carried out.
  • ADK – The “Application Designed Kit” allows companies to set rules that regulate company processes (e.g. deciding where and in what contexts electronic signatures are required) or to optimize all operational workflows to increase personal productivity and process security. Each process step is validated not only through electronic signatures but also by following pre-set rules that help users to carry out the assigned activity correctly.

CONCLUSIONS

SAM ERP2 is a fully-fledged system that allows to manage all company processes in a completely integrated way: PURCHASES, PRODUCTION, CRM, GOODS handling and storage, ONLINE connections with the productive and commercial chain, ADMINISTRATION, CASH MANAGEMENT, FINANCIAL management, MANAGEMENT CONTROL SYSTEMS.

SAM ERP2 is provided with many other functions that are specific to the chemical sector and that allow to validate transformation, packaging, and distribution processes in full compliance with the standards and regulations in force in this sector. SAM ERP2 allows to handle the entire purchase and production

workflow (MRPII), from the management of forecasts, purchase orders and sale orders to the delivery of the final product. It also makes it possible to manage the quality control system as well as the materials flows and transformation processes. By configuring users and “roles”, it is possible to define authorizations and responsibilities in compliance with the specific requirements of the chemical sector. By allowing to define the product “status”, set the validity period, and by ensuring full traceability along the entire transformation and distribution process, SAM ERP2 guarantees absolute operational and regulatory “consistency”, while the Audit Trail and Electronic Signature systems enable businesses to document every transaction that is subject to GMP validation.