ERP Software for the Paper and Tissue converting Sector

ERP Software for the Paper and Tissue converting Sector

The paper and tissue sector is a constantly growing sector of the global economy. Tissue and packaging represent its two main engines.

The paper and tissue sector represents one of the most important industry sectors of the global economy.

SAM ERP2 is a second-generation 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.

SAM ERP2 functions include full control of advanced logistics (supported by the “UCC/EAN-128”, “SSCC” GS1 standards). SAM ERP2 represents an essential tool for certifying the quality of company processes and products in the entire production chain (FCS, PEFC, EU Ecolabel, MOCA certifications).

SAM ERP2 is a powerful, cutting-edge ERP system developed by Centro Software for full and integrated management of companies operating in the paper and tissue sector.
Security, quality controls, traceability and tracking, management of sale and sale attempt processes, relationship with large-scale retail trade, handling of lots and expiration dates, organization of warehouses, internal and external logistics, labeling, barcodes, picking, freight, calculation of net contribution margins… these are only some of the functions that make SAM ERP2 a perfectly adaptable product for every production or commercial business of the paper and tissue sector, whether small or large.

RELATIONSHIP WITH LARGE-SCALE RETAIL TRADE

The complex rules that governate the relationship with large-scale retail trade can be efficiently replicated in the Sales Area of SAM ERP2. It is possible to fully set and manage different levels of price application, discounts on each line, multi-agent options, document promotions and prizes on certain time periods. It is also possible to place campaigns in specific periods and set targets for product groups. This function not only represents an excellent tool for managing and controlling actual sale prices, but it also enables the sale department to guide the sales force in the most competent and efficient way. SAM ERP2 is integrated with the main EDI standards, which allows to improve document flows by limiting manual interventions..

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”.

     

WAREHOUSES, INTERNAL AND EXTERNAL LOGISTICS (EAN, UCC, SSCC, etc.), LABELING, PICKING

SAM ERP2 offers functions to immediately identify and locate products, optimize warehouse spaces and transfer paths, thereby reducing the average time for the preparation of orders, and improve client services by considerably reducing non-conformities due to picking. The Warehouse Module also allows to manage warehouse locations by also taking into account their capacity, handle biohazard procedures, generate and manage loading units, arrange SSCC labeling, and lastly take care of Delivery Notes, Packing Lists, DESADV, etc.

HANDLING OF SALE PROCESS AND SFA

You can obtain the best integration of sales force within the company’s business processes by implementing the Sales Force Automation and Sale Attempt procedures. These tools allow to gain efficiency from sharing new “prospects”, “visit rounds” and credit recovery procedures. Furthermore, these tools allow to easily involve the sales force in activities scheduled in the company’s CRM (interviews, bookings, canvass, etc.). An excellent ‘quick sale system’ is also provided (Orders, Invoices, Delivery Notes) to retrieve data from the sales history to make it easier to order items again and to list replacements and alternatives for each item for the sale process. The ‘License plate/truck’ function is also available to rapidly transfer set amounts of products or lots.

ORGANIZATION OF SHIPPING ROUTES AND PRICE LISTS OF CARRIERS

The transport organization can be optimized by saving relevant data for each loading or unloading point: characteristics of required vehicles, time of collection, need of tail lift, size and weight, and lastly management of the exchange of pallets with clients and carriers. The calculation of additional costs results from the integration of management control functions with the classification of vehicles, management of carrier price lists, and the automatic issuing of freight purchase orders with ‘automatic pre-invoicing’ of documents which can be sent to suppliers in advance for review purposes. Moreover, this SAM ERP2 module is fully integrated with MapPoint and Google Maps to allow a fast and precise calculation of shipping routes and actual kilometers.

“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, with particular attention to formats, in order to setup production processes in the most efficient way possible.

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. Heuristics can be fully configured, which allows to obtain the best scheduling processes for plants and resources. This brings to a balance between setup time and expected delivery dates, as it allows to access different scenarios and to “freeze” the plans that are to be dispatched to MES and monitoring work stations.

REAL TIME CONTROL ON PRODUCTION

SAM ERP2 allows to manage recipes, processing cycles, plant and maintenance schedules, thereby allowing to efficiently plan processing lines and contract work phases. Through the MES (Manufacturing Execution System) it is possible to monitor the production process by integrating at the “border of line” all functions related to sampling and quality control cycles. The handling of lot characteristics allows the system to recommend the best raw materials for each processing. The operating production functions also include the connection to automatic warehouses, loading cells, “silo” warehouses and the integrated management of transactions with Wi-Fi terminals.

TRACEABILITY AND TRACKING

The quality of the products does not only result from optimal production processes, but also from the care put into checking the origin and the usage of raw materials. Management by lots and quality controls, which can be defined for each type of product, allow to comply with the FSC, PEFC, Ecolabel and Moca standards.

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

QUALITY CONTROL (Delivery, Internal/External Laboratories, HACCP, Tools, etc.)

Thanks to the integration with ISO and Vision2000 certifications, it is possible to efficiently manage quality control processes during regular operating workflows, without the need of any additional or asynchronous activities, and in full compliance with product control standards. The quality control functions allow to define control plans for each item and phase, customize testing levels, associate critical points of products and supplier classes, and lastly to configure automatic procedures to pass the tests. For example, each delivery of raw materials might have to undergo measurement and analysis procedures in the internal laboratory, and generation of Non-Conformity reports related to the purchase process (definition of price according to characteristics of product, reclassification, etc.) and to the suppliers’ accounting procedures.

NET CONTRIBUTION MARGIN (depending on performance, weight reductions, maturing, by-products)

The paper and tissue sector is affected by different dynamics for the calculation of the net contribution margin due to various factors that significantly impact on production cycles, such as different performance of raw materials depending on temperature and humidity, as well as other technological and environmental factors. The correct management of weight reduction, related to the isolation or maturing of the products, and the calculation of the by-products obtained from the processing of the main product represent fundamental factors for defining the cost of the items and create a consistent calculation method for real contribution margins.

Conclusioni

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

It is possible to manage different versions of technical datasheet, assign validity dates, and manage characteristics of each product and specific requirements for each client or sale order, thereby guaranteeing a timely response to each client’s every needs.

Integrated logistic procedures allow to manage raw materials through lots or serial numbers, by associating technical and logistic information that are essential for avoiding additional transactions that often generate counterproductive errors while proceeding with the sale order process. FCS (Finite Capacity Scheduling) and MES (Manufacturing Execution System) allow to verify, schedule and keep track of assignments both for traditional resources (work centers, assembly and/or testing teams) and technical departments (which may represent choke points if not well organized).