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How to simplify your ISO 9001:2015 system at production?

How to simplify your ISO 9001:2015 system at production?

How production management software can practically simplify ISO9001:2015 system in your company?

In 5 points we show you how to reduce the number of documents in quality management system and improve the level of work.

How did you come across ISO 9001?

  • Obtaining a certificate ISO 9001:2015 or other quality system was imposed by one of your key Clients.
  • You decided to implement a quality system to standardize procedures and improve functionality as you had some organizational problems.

Regardless of your motivation to make changes, we suspect you might feel a little bit disappointed. Even when you really worked hard to implement the ISO 9001 system.

  • Even though many procedures were created and you agreed in writing the way they should work, it has nothing to do with practice.
  • The production hall workers spend a long time filling different orders, working cards, etc., but this paper work doesn’t translate into a real decision-making process.
  • There are many interesting rules and monitoring procedures, but only on paper, not at the production hall.
  • You are under the impression that your solutions are for your client’s monitoring requirements or for auditors, who come once a year.

If any of the above symptoms apply to your business, check how production management software can help you:

1. You can get rid of binders full of product documentation and make sure your employees always have updated information.

Thanks to the Prodio database of your products, all necessary information automatically goes from operator to production:    

1.You don’t need binders with outdated documentation because Prodio’s database of products updates automatically. 

2. You don’t have to mark and set the version of documentation  – Prodio shares dates of changes and the login of a person who made them. 

3. The problem with “Knowledge management” with ISO 9001:2015 is automatically solved. Some companies don’t know how to deal with required norms. When product data is collected in real-time and next analyzed, this problem disappears thanks to employees’ comments, complaints, or remarks.

4. The employee always has updated information about the product; thus, the standards regarding communication and information flow are met. Thanks to the technology of production, a comment can be directed to a particular operator.

Additional application of this solution:

Influence on Clients’ image for auditors – especially in the case of big companies.

Let’s be honest: the bigger a company is the more probability of using the “old-fashioned” ERP program. Imagine auditors surprise when they see computers for employees at the production hall in small manufacture. Prodio was often a trump card and a strong point in negotiations in automotive industry audits or other important market players.

A perfect place to show correction measures

Instead of creating correction measures, especially for audit, add to Prodio updated manuals or photos of product defects and information about what should be double-checked during monitoring based on real problems you encountered. You will improve actual quality and lower the defect rate and gain the auditor’s respect because of your right attitude to ISO 9001:2015 correction measures.

2. You don’t have to print paper production orders and working schedules.

One of the most important elements of all quality systems (and quite correctly, because it’s one of the main points where complaints arise) is communication between production and the office – which basically means giving commands.

Practically speaking, all parameters are copied from order to a production order and passed onto employees, or a catalog with photocopies and drawings is ready to be taken to a production hall.

Once you use production management software, such as Prodio: 

1. You don’t have to supply any papers to the production – both order and product parameters are in the system. 

2. The employees always know what to do – not only do they have to look into documentation, but your presence at the production hall is no longer necessary because the production plan is available online.

3. No more lost orders and technical drawings at the production hall.

Additional application of this solution :

Add permanently quality control procedures and additional manuals to machines and operations on the production plan.

Instead of putting documents that each employee should know or necessary manuals (ex. machine maintenance) at the production hall, you can permanently add them to the production plan as lines attached to particular machines or operations to eliminate paper documents.

Lower the number of mistakes at the production hall 

We hope that so far, you visualize how different your production could be with fewer products wasted and mistaken orders avoided once the communication between employees and information flow was working efficiently. It’s true –  and as many companies indicate, the changes are immense and effects quite spectacular.

3. You can finally abandon the painstaking filling of work cards and orders at the production hall and increase productivity.

Identification and traceability (possibility of recreating working history) are the basics of quality norms. There is a necessity of registering work by employees hence the overwhelming number of notebook pages, order cards, or registers full of signatures.

Once you use production planning software, such as Prodio: 

1. Instead of writing, it’s enough to use a key-fob and a reader, which replace a signature and employee ID.

2. The whole working history is in the system – it’s created automatically once the working operations are registered in the system by employees.

3. Fast filtering and access to working history – it’s easy to find anything in the system, as the data is stored in the database, it takes only a few seconds, not hours, as before.

4.You can control analyses and monitor efficiency in real-time – this allows you to improve production and find unprofitable orders.

Additional application of this solution:

Normative requirements regarding monitoring and process analyses are met automatically.

You can easily answer the auditor’s question about methods used for monitoring processes: just a few clicks, and you get a satisfactory response.

Improved efficiency of your team

Using a computer or another tool that sums real working time (not a piece of paper where anything can be written) significantly improves work efficiency.

4. Get rid of all forms, which got on your nerves before each audit.

Once you use production management software, such as Prodio: 

1. Ongoing production can be marked with barcoded order cards, printed directly from Prodio – it’s enough to add such cards to each pallet or package to see clearly what they contain and who they are for.

2. Register incompatible products and assess your team from the point of product defectiveness – in Prodio, an employee gives the number of deficiencies and reasons.

3. You have updated order statuses and dates of confirmed lead date – it all goes through the list of orders, which you use daily. Hence it’s updated.

4. You can use Prodio’s ID as a batch number or product ID numbers, which you can place, ex. on the boxes or qualitative documentation.

5. Thanks to additional boxes during work registration, you can easily register a raw material batch number used for making the product. It can be handy for automotive industry companies.

6. The complaints are added to the list of orders – thanks to that, you avoid the necessity of creating an additional list.

Additional application of this solution:

 

Eliminate unnecessary procedures and limit documentation to a bare minimum.

Practically speaking, the new norm ISO 9001:2015 allows to replacement of written documents and procedures with algorithms and programs, which regulate the pace of work. In that case, is there anything better than production management software?

Do you have any questions?

We are glad to help ?

Let’s chat (the right-hand corner of the screen)  or talk on the phone, call us: +48 32  746 61 62

We are happy to hear from you from Monday to Saturday 9.00 am to 5 pm

Stop paying extra to your products  – simple production CALCULATION

Stop paying extra to your products – simple production CALCULATION

Stop paying extra to some of your products!

Calculating production in Prodio system - introduction

Learn about real times and product making costs – calculate production

In the last article you learned how much you can save by introducing a simple production planning– today you we are going to show you how to save even more money, by explaining production calculation.

This manual is for you, if : 

  • You happened to work on a large scale production order and once it was completed and all expenses paid, it turned out there was no profit made, not to mention anticipated earlier bonus.  

  • You are not able to say what your real labor cost are for particular products and what’s real efficiency for particular operations.

  • The employees use paper production orders, which are analysed with delay (or aren’t analysed at all), so your conclusions are based on nothing. 

  • You are under the impression that even though your workers put overtime and claim to do their best 100% – the work doesn’t progress as fast as it should.

  • You aren’t able to compare planned lead times to real lead times, so majority of your production calculations are “wild guesees”.

 

If you answered “yes” at least twice,  you will find below a solution to your problems 🙂

Why paper production orders are misleading?

You can say: “I’ve already got paper orders at the production hall and people copy everything to Excel – do I really need aspecial software to get similar data?”. 

Paper orders have many disadvantages  – where one of the biggest is a DELAY IN ENTERING DATA (it takes time to copy data to Excel).

1. You don’t react fast enough and aren’t able to catch your employee „red handed” once the norms are subpar.

2. You aren’t able to find the real reasons for low efficiency, because having so many orders you can’t remember what happened a few days ago.

3. Your employees fail to fill out documents or they do it post factum, so the data you receive is incomplete or incorrect.

4. You waste money on paying for copying data to Excel – it can cost you more then a 6-month software subscription fee.

5. You have a monstrosity in form of “Excel”, which you find hard to navigate and source required information.

Registering work in electronic system is a must in 2018.  There isn’t much sense in seeking advice on improving work efficiency prior to introducing it, because you cannot work without data.  

Imagine how your work can change, when you are able to open the software and check in 2 minutes what’s happening at your production hall while having a cup of coffee in the comfort of your house. 

Please bear in mind that all disadvantages you read about regard filling paper orders / keeping work notebooks, but not employees themselves. If in you industry it is important for the employee to have actual data at their working station without going to computer desk, you can do it with one click and generate for them paper production orders with bar codes.

Calculating production in practise – learn how much it really cost you to produce a particular detail 

When you set up an account in Prodio you got an access to many different ways of accounting production and sourcing data, which you need. Here are some of the most interesting options: 

1. Work history – fast sums accordingly to personalized filters to help you calculate your production  

The bookmark work history is an easily accessible vault of information regarding working history of the whole company, where it’s saved every clocked: check in and chech out, number of pieces made, quantity and number of shortages, quantity / name of raw material used.

What’s more the software sums in the background: how long was working an employee and what was their efficiency, and if there was a norm set for particular product, it also shows how many percents of this norm a particular employee achieved. 

This vault of knowledge allows you by using filters, not only find any required operation in work history, but also gives you almost unlimited possibilities of summing (based on any parameter wanted), so you it would suit your way of production accounting. 

Rozliczenie produkcji bieżącej - historia produkcji zleceń rodukcyjnych

2. Check quickly how long it took to complete your order and whether there were any discrepancies between estimated time and lead time – total order calculation

Production accounting for order positions should be one of your favorite functions (you can find it by clicking a magnifier tool in the bookmark “Orders”). There you will find:

  • total number of working hours, which your employees spent at production divided by particular operations,
  • total number of working hours for all operations for a given position on the order form,,
  • estimated times based on technology of the product, which describe the lead time.

Practically speaking when you look only at that simple table in production accounting for particular order, you will find out whether order estimated time was sufficient and whole production profitable.

Rozliczenie produkcji dla całego zamówienia - suma czasu założonego i realizacji z zleceń produkcyjnych .

3. Do you need more advanced reports or maybe wish to account work based on number of pieces made rate – easy production accounting thanks to Ecxel export 

When it comes to advanced production accounting each company does it differently, so creating a standarized report in Prodio would be impossible.

That’s why we prepared a complete Excel export tool, so you could source required data, as well as the whole working history and have it saved on your harddrive independendly.

When you use for production accounting the number of pieces made rate, you will find here everything you need: empoyee name and surname, type of operation, nimber of pieces made, dates – just one crosstab and you are ready to sign paychecks gotowe :).

Crosstables are the best ways to get your reports, so we definately recommend them. To prepare a report based on a crosstable you have to:

  1. Mark data tables (from boxes A8 to the last row with data and collumn N) in downloaded work production history.
  2. At the top bar in MS Excel select “Paste” and “Crosstable”.
  3. Nest, in the righ-hand menu select what you want to be seen as collumns, what as rows and what should be calculated in  your report (and you can also choose what should be displayed, sums, avarage or number of occurence).

If you wish to learn more about crosstables in MS Excel (and it’s one of the best functions of this programe), there are many simple tutorial videos on YouTube explaining how to use them – just click the following link.

Rozliczenie produkcji dla całego zamówienia - suma czasu założonego i realizacji z zleceń produkcyjnych .

4. Advanced production accounting and reports in Prodio analyses module 

We will disscuss in details advance production accounting based on Prodio analyses module later , because once you start your adventure with Prodio, you don’t have enough data for online system.

Eventually you will be using analyses module in Prodio and you will be able to:

  • verify aggregated machine occupancy in particular weeks of the year (both for past and upcoming periods based on production schedule),
  • compare productivity of your whole production and productivity of particular employees – percentage of time spent on machine work (check in and check out times),
  • total sum of working hours and time spent at work daily, weekly and monthly,
  • …and many, many more 🙂

 

Rozliczenie produkcji dla całego zamówienia - suma czasu założonego i realizacji z zleceń produkcyjnych .

5. HR and payroll reports, work time accounting 

Thanks to a simple build-in WTR module in Prodio (Working Time Registration) your accountant / external accounting firm will have much easier task.

Open the program and go to left menu, Analyses -> Employees – HR report and you will see working hours chart for any required month, which you can easily export to PDF file.

If you need more detailed view regarding check in/ check out hours daily and for each employee, you can see it / export in left-hand menu -> Working time (WTR)

If you want to learn more about Working Time Registration (WTR) with RFID key-fobs check the following article.

Rozliczenie produkcji dla całego zamówienia - suma czasu założonego i realizacji z zleceń produkcyjnych .

Do you have any questions?

We are glad to help ?

Let’s chat (the right-hand corner of the screen)  or talk on the phone, call us: +48 692 450 815

We are happy to hear from you from Monday to Saturday 8.00am to 8pm

Try it for 14 days and change your company!

Straight away you get a complete access to all functions, so you can fully test the program at your facility. You don't have to leave you company data or telephone number- it's enough to provide your e-mail address.
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More then 50 tricks, how to use your Prodio’s account better

More then 50 tricks, how to use your Prodio’s account better

Prodio TIPS & TRICS

Thanks to these tricks, you will make a better use of your production system and adjust it to your needs with ease.

More then 50 tricks, how to use your Prodio’s account better.

Learn how to even better plan your production, account work at the production hall and adjust the software to what you need. This list is being constantly updated thanks to our Clients input, observations and experience. 🙂

Adjust software to your needs:

  1. Additional parameters of the product
  2. Prodio on your mobile phone
  3. Your logo in Prodio (also in the display at the production hall)
  4. Personalized order and number of collumns on particular lists
  5. Turn on product pricing service, to control your orders better
  6. Hide Prodio’s order numbers and use your numeric system
  7. Default units for measuring efficiency 
  8. Personalized machine orders on the production plan
  9. Set your “favourite” production plan
  10. Different machines displayed on different desktop panels

More comfortable work every day:

Orders:

  1. Create new products directly when adding a new order
  2. Production planning from the orders level in one click 
  3. Fast overview of total order progress
  4. Check, if you already printed technological manual to your order 
  5. Print your order (technological manual as well as bar codes to register work)

Production planning:

  1. Change the order of working operations on the prarticualar machine with ease (on the production plan)
  2. Tags for marking simultanious and urgent operations 
  3. Use tags to see clearly the product, which goes multiple times through the same machine/opertation
  4. Plan production more comfortably with a horizontal view of the working plan
  5. Automatically hide machines without orders assigned
  6. Hide machines temporarily at the production plan
  7. Minimize particular machines at the production hall
  8. Assigning employees to particular jobs
  9. Hide particular orders from a production plan
  10. Make communication at the production hall better with operation predecessors
  11. Faster production planning thanks to planning tips
  12. Checking individual machines and workers avaliability within the production plan

Production hall view 

  1. Emloyees notice board
  2. Fast orders search in the production plan (also in the production view)
  3. Make Prodio’s display better at the production hall 
  4. Hide your Client’s data or the order before production
  5. Find an employee faster on the list
  6. Don’t let workers start their work without clocking in at the production hall
  7. Show your employees at the production hall how much working time is left to exceed the set norm
  8. Set locks, so worker won’t be able to work on two orders simultaniously.

Accounting and monitoring

  1. Registration of employees check in/check out and comparison of working time on machines and employees
  2. Track workers who hang around without working on the machines
  3. Register separately time when a machine works without worker’s supervision
  4. Workers check in / check out registration 
  5. Correct the history and number of items made 
  6. Register shortages at production, a batch and the amount of raw materials used
  7. Compare with one click planned order completion time with real completion time

Interesting uses prompted by our Clients:

  1. Follow work at the construction and graphic departments
  2. Large files without uploading to the website
  3. Treat contractors as machines or operations in product technology, to follow externally outsourced procedures
  4. Register jobs not connected with production ex. cleaning, maintenenace or service

Personalized order of machines on the production plan

In most situations it is recommended the order of machines/workling stations shhould correspond with their true setting at the production hall.

How to do it:

In the left-hand menu choose Settings, and next Machines.  

The order of machines can be changed by dragging up and down items on your list.

You have just changed the order of machines on the production plan.

Changing the order of work on the particular machine 

The 90% of Prodio’s Clients follows the rule, that the list of tasks for particular machine is worked from the top to the bottom – where a worker always chooses the first incomplete order.

How to do it:

Choose the machine where you would like to change the work order. 

Click and hold the cross button and then move it up or down. 

You have chaged the order on particular machine. 

Emloyees notice board

Information about “working Saturday”, unloading the truck at the end of a working day or other important notices – now they can be visible at the production hall without a necessity of additional phone calls.

How to do it:

Go to production plan and open “Notices”.

You enter the notice which you want to appear at the production hall and click “Save”. 

The notice should be displayed at the same time on workers production plan at the production hall.

Searching and narrowing down results at the production plan 

Would you like to be able quickly to narrow down your production view to a particular employee, order or product? Use a browser (it works on both employees and managers views).

How to do it:

Once you have opened you plan click magnifier icon,

or twice letter F on the keyboard.

Wpisując tekst w pole wyszukiwania automatycznie zawęża się plan. Jeżeli wpiszesz w wyszukiwarkę nazwisko, lista filtruje się też do przypisanych zleceń pracowników.

Planning from the orders level

You can schedule the order directly from the order level, instead of first clicking production plan and next choosing an order to complete. 

How to do it:

Go to the list of orders. 

Click on the gear icon at the order, and next “Schedule” button.

The window “AdD to production plan” will open automatically. 

Make Prodio’s display at the production hall better 

Make your workers life easier and prevent them saying: “I’m sorry boss, but I closed it down by mistake and didn’t know how to log in”. 

How to do it:

At the production hall set Prodio as the start website or add it as a bookmark to favourites. A detailed manual how to do it you can find in Help window of your browser (we recommend using Google Chrome).  

Save log in password in you browser or check “Remeber me” – so your Plan would always load on opening.  

Once you display it at the production hall press F11 on your keyboard, so you can enjoy the full screen view. 

Prodio on your mobile phone

Manage your production from anywhere in the world – log in via your mobile phone.  TIP: Registration of production will also work on tablets and smartphones.

How to do it:

Open a web browser on you mobile phone and enter your account address. 

Log in to your manager’s account.

Add a website as a bookmark – next time you can access it faster.

Work check in / check out modification 

It sometimes happens that a workerer forgot to register their check on / check out – you can fix it, so the calculations and sum will be correct.

How to do it:

In Setting menu click a “Working time” bookmark.

Find incorrect or missing.

Make time correction.

Correct the history and the number of itemes made

Sometimes it happens that an employee forgot to clock in/ clock out – you can correct it, so the total number will be also correct.

How to do it:

Choose the order, which history you would like to modify and next click “See the history of the order”.

There is an “Edit” button below.

Wpisujesz właściwe dane i zatwierdzasz niebieskim przyciskiem.

Assigning employees to particular tasks 

Sometimes you need ot assign a particular person or a group to complete a task from the working schedule.

How to do it:

Choose an order to which you would like to assign employees and click “Edit production order”.

In the box “Assigned employees” choose one or more person and next click “Update”

Employees initials appeared on the production plan.

Minimazing particular machines on the production plan

Sometimes to make your working plan more clear, you can minimize the list of machines.TIP: this operation has no influence on other users or production hall.

How to do it:

On the production plan click the arrow symbol, located by the particular machine. 

Minimized lists for particular machnes.

Aby przywrócić poprzedni stan, powtarzasz operację.

Automatically hide machines without assigned orders

When some of your machines are rarely used and prevent you from seeing a clear working schedule – you can automatically hide them, as long as there aren’t any tasks assigned to them.

How to do it:

Znajdź na planie maszynę bez pracy.

In the left-hand menu go to “Settings” and next “Main” and check the box “Hide machines/operations without any orders assigned”.

Check, if the machine is hidden. 

Hiding machines temporarily on the production plan

Sometimes a particular machine is not used for a longer period of time, so it is worth to hide it. TIP: This operation  has influence on other users and the production hall view.

How to do it:

In the left-hand menu go to “Settings” and next – “Machines”.  

Find on the production plan the machine, which you want to hide and click a pen symbol. 

Change status “Active” from “Yes” to “No” and click “Update”.

Hide orders from a production plan

Completed job, malfunction, the lack of raw materials or a very long list on the machine – there are many reasons why you might want to hide some orders from the plan.

How to do it:

OPTION 1: From the production plan level choose orders to hide, click a gear icon, and next “Hide the order”. 

OPTION 2: From the level of the list of orders (“Menu”, and next click “Orders”) choose all orders to hide. 

To bring back the order to plan, filter the list of orders and activate the hidden ones. 

Hide your Client’s data or the order before production

Sometimes it is better for your workers not to know who is the customer. You can hide that information with one click.

How to do it:

Consider if it is a good idea to hide Client’s data or information about the order from you workers. 

Go to “Settings”, then “General”. 

Here you can make changes regarding your Client and the number of order. 

Different machines displayed on different panels

Is your production hall rather big with computers at opposite ends or maybe has a few seperate rooms with a computer in each of them? Display in each room relevant machines only.

How to do it:

Create a new “Production panel”. To do that go to “Settings”, and next “Production panels”. 

In the “Settings” menu, find “Machines” and click “Edit”. 

Move relevant machine to a newly created “Production panel”. 

Additional product’s parameters

Depending on the industry you work in, you need to collect different information about products – you can do it precisely and the software enables you completion.

How to do it:

In the left menu go to “Settings”, next “Additional baxes”, and “Add atributtes”. 

Create a new parameter, which you want to have for your product, ex. “Color”.

Now for each product there is an additional box and enetered parameters are displayed at the production hall. 

Registration of employees check ins/check outs and comparison of working time on machines with presence.

Regardless of having paper list or electronic cards system, it’s worth to use this Prodio’s feature. 

How to do it:

The employees register check in/check out time by using suitable buttons on the production plan. 

All history of check ins/check outs you can check in settings by clicking “Working time” (you can also export it as .xls).

When analyzing you can also sum up (and compare) machine working time by weeks and months.

Your “favourite” production plan

When you have many machines at the production hall, there is always that one “the most important”, which you prefere to see firts, when opening the software.

How to do it:

You decide, which production plan you want to see firts.

Go to “Settings”, and next “Users” and start editing a profile. 

Choose a production plan which you want to display firts, then click “Update”. 

Create new products directly when adding an order

How to do it:

When you add an order write the name of the product in a dedicated box. Click “Enter” to create a new product. 

Find an employee faster on the list

Once you employ several dozen people it may prove troublesome for them to find their name on the list each time they start or finish work. A browser comes in handy.

How to do it:

An employee opens a production order and writes next to it their name. 

The list of employees narrows down, so it’s easier to find a right person. 

Default units for measuring efficiency

Yuo can decide what is more convenient and set as default the method of measuring efficiency: numbers of pieces per hour or lead time.

How to do it:

In the left menu go to “Settings”, next “Main settings”.

Select a default unit of measurment.

Next time a technology of product is created, your default unit of measurment is already set.

Prodio in construction and graphic design departments

Would you like to manage better your designers and graphics, optimize ther work and know excatly how much the project costs you? Treat them as “machines”!

How to do it:

Create a Production Panel ex. “Graphic design department” (click respectively “Settings”, “Production Panels”, then “Add”).  

Add graphic designers and constructors as machines and assign them to “Graphic  design department” panel.

Choose “Graphic design department” as a production hall, give log in data to your graphic designer and you can start planning their work. 

Large files without uploading them to the website

It is sometimes much more comfortable to keep large files (ex. at the pront shop) as links in the intranet then uploading them to the website.

How to do it:

Create product’s attribute ex. “Links to files”, go to “Settings”, next “Additional boxes” and “Add attribute”.

In windows File Explorer copy the file path or folder path from LAN network, which you want to share. 

Go to new product and when you’re editing it paste the copied path in the box “Links to files”.

Turn on product pricing service, to control your orders better

When you accept new orders from your Clients directly in Prodio, you don’t have to remember selling prices. You can export prices together with orders, passing them onto accounting department or invoicing software. This function can eventually help you to compare production cost to completion cost.

How to do it:

In the left menu choose “Settings”, next “Main settings”, where you turn on option: “Turn on producta and orders pricing (additional boxex – the price, VAT rate, currency). 

You can permanently assign prices to products.

Once you enter a product or an order you can add thei selling proce or VAT rate. 

Create new products directly when adding an order

Do you accept many single products and don’t want to waste time preparing sophisticated technologies for them? Add technologies while creating an order.

How to do it:

Write the name of the product in the dedicated box while adding an order and press “Enter” – a product should be created straight away.  

Tags for marking parallel and urgent operations 

Sometimes you need your workers to prepare simultaniously a few elements at the same working station (ex. burning sheet metal).

How to do it:

Wchodzimy w „Edycję zlecenia” dla pozycji, jaka ma być wykonywana równolegle z inną.

In the box “tags” write “parallel” and click enter.

Repeat the same action for other parallel orders. you can add other tags ex. “URGENT!”. 

Use tags to see clearly, if the product goes through a machine/operation multiple times

there are some processes where a product goes through the same machine/operation multiple times and it’s hard to pin point which stage it is at. Tagging seems to be a great solution.

How to do it:

You can create and modify tags in “Settings”. Using contrasting colors lets workers quickly identify the tag. 

While creating the technology of product, you can use the same machine tagging particular operations without a problem. 

While planning tags will be automatically dragged to the production plan and visible from a distance to employees.

Fast overview of order’s total progress

There is no need to psend long time on searching work operations history, to find out at which stage your order is or how much time took to complete the order.

How to do it:

On the list of orders click magnifier symbol (check first wheter the order grouping is turned off), to see summery for each individual machine: planned time, completion time, number of pieces made. 

Treat co-operators as machines or operations in technology of products

Sometimes outsourced operations are a very important technological element and an employee should know whether the product has already returned ex. from anodising.

How to do it:

Got to “Settings”, next “Machines” and create a new machine with the name of outsourced process ex. “Anodising”. It would be perfect to place it at the a different panel named ex. co-operation.

From now on a stock boy passing thep goods to a contractor can click start for “Anodising”, and on returnig goods marks the operation as completed. All workers at the production hall can see whether they can continue their work.

While planning tags are automatically dragged to a production plan and they are visible form a distance fo all employees.

Register separately time when machine works without worker’s supervision.

In some manufactures machine work without employees supervision – ex.CNC machine can be left turned on all night. Register its work separately, so it won’t be confused with labour costs.

How to do it:

Go to “Settings”, next “Employees”. Create a new employee named “Automate” with a simple PIN code number.

From now on an employee clocks in on the machine a new “Automate” employee.

IT’s a good idea to assign additionaly one RFID key-fob to “Automate” employee, to make clocking precess easier.

Register production shortages as well as the batch and the amout of raw material used.

If you want to seal a production process even further start registering the reasons for shortages and the amount of raw materials used by the employees.

How to do it:

Register additional paramenetrs is very easy and accessible all the time to all wrokers. It’s enough to fill out extra boxes on the porduction plan.

To see which data is entered by the employees, you have to switch on additional collumns in work history. 

Effective communication at the production hall with operation predecessors

On the production plan orders for which the previous operation hasn’t been completed, are automatically marked with a dark color. For example: as long as the operator of the milling machine hasn’t finished his work, the workers responsible for sanding won’t be able to see the order marked in dark color.

How to do it:

How does it work?

Widok poprzedników można włączyć i wyłączyć w dowolnym momencie. Nawet na wyłączonym widoku domyślna kolejność wykonania zapisuje się z każdym nowym zaplanowanym produktem z uzupełnioną technologią. Włączenie i wyłączenie widoku poprzedników następuje w bocznym panelu lub w ustawieniach głównych programu.

Hide Prodio’s order number and use your own numeric system

Do you feel attached to numeric system you used before implementing Prodio? You can still use it, without worrying about Prodio’s numbers.

How to do it:

In the left menu to “Setting”, next “Main settings” and select option: “Mark to hide order’s number on the production plan”. 

Next, on the list of orders and others, hide PRODIO’s ID, and move to the first position “External order’s number”.

Register jobs not connected with production ex. cleaning, maintenance or service

To mange time better and further seal your production management, it’s worth to register all operations not only the ones regarding production directly.

How to do it:

Add a few products such as “Cleaning” or “Service” and create a new order for many items. 

Add a new machine to a production plan and name it “Different works”. From now on all employees could register time spent on doing these additional works. 

Compare with one click planned time and real order completion time.

Thanks to this solution you can easily check progress, without switching between different bookmars, and know whether the order is abve or under the line. 

How to do it:

Click a symbol of magnifier on the list of orders (check if order grouping is turned off first). Then you can see a summary for each individual machine as PLANNED TIME and REAL TIME and number of pieces made.

Don’t let your workers to start work before clocking in their entrance ar the production hall

If you want ot make sure that an employee won’t forget to clock in on entering a  production hall – set a lock and make it impossible to start work without clocking in.

How to do it:

Go to “Settings” and next to “Main settings”, then check the option: “Don’t let workers start their work without “clocking in” firts..

Check who is clocking in and not doing any work on the machines 

One look at the production panel and you will be able to see how many people just sit around not doing any work, and modify the working schedule to assign them some tasks.

How to do it:

Each worker who clocked in at the production, but failed to start work on the machine is marked on your desktop panel by flashing red symbol.

.   

At any time you can check in the tab “Analyses” updated work overview. It will show you how many working hours each worker has, and how many of them they spent  working on the machines.

Work more comfortably thanks to horizontal working schedule view.

Thanks to horizontal production schedule you can see more and scrolling between windows is also more comfortable.

How to do it:

Faster production planing thanks to planning tips

Use software’s automatic planning tips to help you set the starting and finishing time for the working schedule. Based on time of the last production order for the individual machine / operation the software automatically sets it as the starting time for the said operation, and the finishing time is calculated based on a production technology 

How to do it:

Go to settings and check “Planning tips” box
Właczanie podpowiedzi odnośnie planowania produkcji

When you enter many different jobs at the same time, the separate orders will indicate the finishing time following their efficiency rate, and you will be able to see a working schedule fullfiled daily, weekly or by the end of working shift

Checking individual machines and workers avaliability within the production plan

Thanks to this function you don’t have to worry, that you doublebooked a machine or an employee. You can monitor progress and track stages of work. What can you check using this function: 

  • If you didn’t assign more then one task to the same machine or operation at the same time.
  • If you didn’t assign more then one task to the same employee.
  • If the following operation in technology:
    • does not start earlier then the previous one,
    • does not finish earlier then the previous one,
    • the software accepts a situation, when two operations are simultanious or when the second operation starts slightly later, but finishes at the same time as the first one.

How to do it:

Go to settings and check “Planning tips” boxWłaczanie podpowiedzi odnośnie planowania produkcji

Plan your orders as usual and then press the “Check occupancy” button  

sprawdzanie poprawnosci zlecen produkcyjnych

Check displayed errors

Show your employees at the production hall how much working time is left to exceed the set norm

How to do it:

Displaying a history of operations and normed working time left at the production hall is turned off as default – but if you make a norm for the product automatically your employeess will see it at the production hall. 

Check if you already printed technological manual to your order

How to do it:

On your list of orders we can see, which order bar code cards have been already printed.

Printing production orders (they can be also used as identification cards at production)

More on using bar codes in Prodio: SEE MANUAL.

How to do it:

Zlecenie produkcyjne - druk pojedyczego

If you want to print cards for more positions. you can check all positions you need on the list, later choose “Checked” and press “Print”Zlecenie produkcyjne - druk wielu

Set locks, so a worker won’t be able to work on two orders simultaniously.

How to do it:

After turning on in general Settings option “Let a worker work on one order only”, the worker who will try to start the next order will receive a message to finish a current task

 

First steps in Prodio – 5 minut manual

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10 ideas how to produce more efficiently – a manual

When each employee knows what to do – your simple online production plan

When each employee knows what to do – your simple online production plan

Your magic board with always updated production plan

First steps in Prodio - how to use production planning

That’s it! You will not waste your money!

Have you recently experienced any of below problems which cut your profits: 

  1. The employees on stand by waiting for you to assign tasks to them personally.
  2. Chaos at the production, which even if you put in extra hours, is not changing into increased productivity.
  3. The employees wandering aimlessly, asking about progress or whether the element is ready at the machine.
  4. Stressful situations caused by lack of control and inability to pinpoint your orders status.
  5. Incomplete information, which stops you from accepting extra work or slowing you down, as you don’t know what’s the capacity of individual machines.

If you answer yes at least once, there is good news – the solution is within your reach and it is production planning. 

Always updated lists of tasks for each operation or individual machine – Prodio’s production plan.

  • The data is always current as computers at the production hall are able to exchange information with your personal computer online and updated production plan is always displayed.
  • At any time you are able to change work order and add new tasks (from manager’s account). They are straight away displayed at your production hall.
  • The employees are able to see a simplified view only and don’t have access to all functions (ex. checking Clients, products), but they can check in / check out their working time. 
  • For better communication you  and your employees both can add to production plan comments (they can be displayed at the plan straight away).

Production plan as easily accessible list of tasks 

What’s the easiest form of assigning tasks that everybody understands? SIMPLE LIST OF TASKS, that’s why in Prodio employees see production plan in a form of list of task for each individual machine / operation and know exactly what to do and in which order. 

  1. The employee always chooses the first from the top task on the list.
  2. Once the task is completed it’s marked green or it dissappears (depending on settings) and the employee can move onto next task. 

You can change the order of tasks from your computer – just drag the particular task up or down to the required position on the production plan. All changes will be visible within a few seconds at the production. What’s important you can react quickly – because you see who is working a particular task and what’s the progress. When there is a problem with completion of order, employees can leave a comment, and you will see it as a pop-up cloud regarding last operations.

Production plan set for machines or operations?

In Prodio you decide how a production plan will be set, by ordering tasks – by simply naming particular lists (Settings -> Machines/Operations). Think how you see your production and try to replicate it in the software.

Tip: different manufacturers use categories such as “Preparing technology” or “Cooperation services” and mark them as operations on the production plan, which allows them to see production as an overall technological process.

The production plan can be divided into clear desktop panels, separate for each production hall or group of machines

  • You can have any number of computers / tablets at the production hall and you can display all machines on all computers or devide them into desktop panles. 
  • The devision of the production plan to different desktop panels makes it clearer for employees – one computer displays only thiese machines / operations, which are necessary. 
  • You, as a manager, have a full access to all data and desktop panels directly from your computer.

 

You can see machines occupancy and you know straight away whether you keep a deadline

In a small manufacture there isn’t time to waste it on setting a precise production schedule/ There are too many variables and there is too much work, so the constant corrections would make it pointless.

All you need is a clear view, how much time is left for particular operations, a forecast of machines occupancy – to make a decision whether you are able to accept further orders. This is a practical solution you get from preparing a production plan in Prodio.

Additionally the software will let you know which orders are overdue, marking them red – and you can receive an e-mail with this information if requested. 

You know exactly what is happening at the production hall and can react adequatly

Prodio gives you a complete array of tools, so at any time you know:

  • Who is working, what time they started, wheter they complete machine tasks.
  • Which machines / operations are now in motion and who is working and where.
  • Which stage are particular oreders at, and who is working them.
  • What and how efficiently has been produced and if there were any important comments during prodution.

Obviously, you can access getprodio.com not only on your computer, but also on your  smartphone – so you have always your production with you.

Your employees will not waste time to find out whether they can start the next procedure or is it still underway. 

That’s it! No more wandering and asking what to do! The bigger the production hall, the worse it usually is and the workers waste time checking whether they can work on the said item or if it’s still waiting for completion at the previous machine.

The good production plan should show employee visually not only what they have to do, but what from the list can be actually made.

Production plan objectives 3

Apart from marking with the dark color, the employee at the different production hall / different operation can see what stage is the product at, how much was already completed (ex. can they take the first pieces from the milling machine and start sanding).

 

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Which production management software / ERP is the best for a small manufacture?

Which production management software / ERP is the best for a small manufacture?

Which production management software / ERP is the best for a small manufacture?

Practical guide to help you choose the best production planning and production accounting software, and which will protect you from bad investments.

 

 

Production management software – this is a phrase you probably typed in Google searching for a solution to your production problems,  but soon were surprised to find thousands of search results, each company offering you their great product, so now you are none of wiser and still have a dilemma what’s best for your business.

 

 

 

 

That’s why here, we are going to help you to choose the best tool for your production planning. Calculate work, get rid of paper orders, and last but not least, improve efficiency and gain control over processes at the production hall.

 

This guide will tell you:

 

 

PLEASE NOTE: This guide is addressed to MICRO and SMALL PRODUCTION MANUFACTURERS (5-40 people at the production hall), which intend to achieve positive effects quickly, without involving a complicated, hundred of thousands of dollars pricey system. 

 

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Try Prodio without any commitments - you have 14 days to check all of its functions in practice. After your trial period ends you can simply leave your account or continue work as our Client.

 

 

 

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This is the summary which sets out the main points of the whole article:

1. Which production management software is the best to choose (graph)?

 

 

2. Which production management software is the best to choose (table)?

The size of your company

When you offer: 
simple products / production services

When you offer:
complex products with a big share of purchased parts 

Large
( +50  people)
  • Corporate MES with automated scheduling and connection to machines, ex. Queris or Żbik
  • Complete production system ERP + MES + WMS, ex. SAP Business One
    with extentions
Medium 
(25-50 people)
  • Advanced production management software such as MES, ex. Plan-de-CAMpagne 
  • User friendly production management software which uses RFID cards, ex. getprodio.com – premium package
  • Advanced production system with MES and accounting integration,  ex. Qcadoo
  • Simple ERP class system , ex. Modus

Small
(10-25)

  • Advanced production management software with accounting integration, ex. Qcadoo
  • Simple ERP class system , ex. Modus
Micro company
(up to 10)
  • Using completion in accounting software
  • Extended spreadsheet / free Google Docs
  • Simple production addition for calculation and accounting systems such as ex. MRPeasy

A short explanation of the basic terms used:

  • Accounting and inventory software probably you’ve already got it. For production, it only offers a completion outlook (it shows what consists of which elements).
  • Production management software (MES) – apart from production planning, we access a production hall, where employees register their work.
    • simple (MES) – enables easy production planning, registration of working time at the production hall or calculating efficiency and finally abandoning paper production orders;
    • advanced (MES) – advanced production planning (including semi-automatic), extended registration, services, full materials cycle  – however less flexible. It is very often integrated with accounting and replaces a full ERP;
    • corporate (MES) – it usually requires co-operation with the ERP system. Automatic planning is very often connected to machines with artificial intelligence elements.
  • ERP system  – a wide array from a few hundred to a few million dollars; practically speaking, the difference between ERP and a good accounting and inventory system is that ERP plans what and when should be purchased based on orders. Please note: it doesn’t reach a production hall, so it requires the addition of MES or another module.
  •  RWT system – registration of working time (check-ins and check-outs). It is usually a production management software component, or you can buy it separately, ex. with the check-ins/check-outs monitoring system. 
  • WMS system  – for advanced inventory management, usually works together with bar codes and high stockpiling.

Why ERP systems are not suitable for small manufactures:

  • ERP will not work well if it doesn’t get lots of (even sometimes obvious) information. Hence you will have to spend long hours adjusting this system to your needs;
  • You have to run everything perfectly, or your stocks will show such great discrepancies that you will need to prepare separate documentation;
  • Forget flexibility – in the ERP, and everything must be prim and proper, with accompanying document;
  • ERP-s  usually don’t have a production extended module, so you need to buy an external MES module or the one recommended by the software producer;
  • Be prepared for high cost at the start, and multiply the offer you got by two.

Potential traps for small manufacturers: 

  • Free production management software is usually a cheap marketing gimmick. Only the licences for basic modules are free, and companies make a fortune on implementation services, and you get a product without any technical support.
  • Production management software integration with the accounting and inventory system  – as it happens, due to imprecise technologies, systems will not integrate, and you may waste lots of time on detailed technology descriptions.
  • Lack of online access –  in practice, the smaller a company is, the more SECURE, futuristically thinking, data storage in the cloud should be.

Which production management software, ERP do you need?

The idea to have an ERP production system, which is an “all in one” solution, in practice doesn’t work so well for small manufacturers as it seems at first glance. Look at the graph and choose your situation to find the best solution (the vertical line indicates the number of employees. The horizontal line describes how complex the average product is).

 

 

1. For simple products, produced mostly in-house:
(ex. machining / CNC, plastic/injection moulding industry, rubber products, cardboard packaging, simple woodwork and carpentry, printing shops/printing, steel constructions)

Challenges to deal with: better production management, work planning: the employees must know what to do, how and when, real-time production registration – you know what’s completed, how efficiently, in which time frame and at which cost.

Suggested solutions Micro company (<10 people):  

Suggested solutions Small company (10-25 people): 

Suggested solutions Average size company (25-50 people):

  • If you intend to keep it simple and you don’t need a connection with warehouse and accounting:
  • getprodio.com/pl optimal packageRFID reader (Read more: simple production management software).
  • If you wish to have an accounting module and a connection between warehouse and materials used: advanced production management software – simple MES (read more), ex:
    • metal industry, plastic ex. Plan de Campagne,
    • other industries ex. Qcadoo, MES.

2. For more complex products, where there is a need for externally purchased elements/ operations:
(ex. robots production, exhibition stands)

Challenges to deal with: better inventory-purchase procedures, especially if the product consists of tens of elements, often purchased externally.

Suggested solutions for a Micro size company (<10 people):  

  • Extended Google Docs sheet shared with the office staff;
  • Using completion module in accounting and inventory software, ex. Sybiekt GT or ERP Optima XL.
  • Suggested solutions for a Small size company (10-25 people):
  • Production addition to accounting and inventory system targeting inventory planning, ex. MRPeasy.
  • Suggested solutions for an Average size company (25-50 people):
  • If you wish to keep your present accounting system: advanced production planning and registration system integrated with Optima / Subject, ex. Qcadoo.com (from about 1 400 zł PLN per month + implementation).
  • If you wish to implement an accounting system from the beginning: a simple integrated system with ERP or RHO Modus functionality.
  • If you estimate that your company will grow fast: wit’s worth considering investing in complex tools offering cloud storage such as ERP-s.

Take a shortcut and start planning your production online.

What is what exactly and how it can be used
(production management software – MES, ERP systems and so on)

We have to make an exeption here, because there were numerous situations, when a company spent 50 – 200 ths. dollars on ERP system, only to discover later, that it doesn’t reach to a production hall!

1. Accounting and inventory software with additions

Perhaps you already use it in your company. The Polish market’s best known is Comarch Optima, which gradually had been more and more expensive, and suddenly became an ERP Optima (it’s an ERP only by name 😉 ) and Inserted Subiekt GT, which is a good value for money. Both programs can be recommended, although neither of them is a masterpiece nor is a flop. What’s important they are going to move to a cloud – which might generate future problems.

The basic functions of accounting and inventory software are:

  • Sales (which is everything connected with issuing invoices);
  • Orders (which means accepting the Client’s order and making a product reservation in the warehouse);
  • Stock  (states, WZ / PZ, also very often orders from providers);
  • Completions  (based on completed order and product parameters, the stock updates automatically);
  • Simple CRM (which functionality leaves a lot to desire). If you don’t know what CRM is, click here to read a great article prepared by Rafał from  informatykawfirmie. pl website.

If you wish to have access to production, you buy a simple but separate (or integrated with accounting program) production software.

Simple production additions to accounting software

Example software:  Apator Mozart

Apotor Mozzart - Widok ze strony producenta

The price is based on the offer presented on the producer’s website:  licence from 1 950 zł PLN per working station + implementation.

The principles are to expand your accounting and inventory for easy planning of purchase and production to make complex products to fulfil your orders.

 Main target: 
  • to facilitate the production of sophisticated, multi-element products/complex products, where managing the inventory is of key importance,
  • to create work schedules connected with ordering parts (usually those schedules are for the manager, not for a production hall).
Functions:
  1. Materials planning/products balancing.
  2. BOM-s (products “tree” – which parts it consists of).
  3. Inventory and calculation of semi-products / products.
  4. Advanced cost calculations.
  5. Work schedule, according to BOM-s.
It’s recommended for:
  • the size of a company:  practically speaking form 2-3 employees at the production hall up to about 10 people (when number exceed, it might prove uncomfortable to register production),
  • industries: complex products, were more important is purchase planning and monitoring of semi-products then production management at the production hall ex. If you produce sophisticated farming machines on a small scale.

2. Production planning software (MES-es)

Acronyms and abbreviations tend to be quite fashionable, so most companies with an independent production management system at the production hall boast to be an MES (which stands for a “Manufacturing Execution System”). The role of MES-es is much bigger and includes complete production service, planning and accounting.

For example, even the simplest monthly subscription to Prodio. Pl software (197 zł PLN per month) can be called MES: it reaches production, employees can see the working plan, and a real-time registration of work.

2.1 Simple MES-es – production planning, registration and accounting software dedicated for small manufacturers

The principles are simple – you leave behind your accounting and inventory system and start to monitor production comfortably with a new production management software. This tool is great if you want to abandon paper production orders and have full control over your production from any place in the world.

The example software: getprodio.com

The prices based on an offer from the producer’s website: monthly subscription from 197 zł PLN net per company

  • Implementation costs / set up: 0 zł PLN. The Client can set up the software themselves using the configuration tool,
  • Update costs: 0 zł  PLN (it is always updated),
  • Equipment needed: simple laptop / computer with Internet access, RFID readers + key-fobs.
Target:  

To monitor and better organize production at the production hall, your employees know what to do, in which order (they have a schedule at the production hall), and you know lead times and efficiency.

Functions:
  1. Creating a production plan where orders are displayed at the production hall.
  2. The production employees can register operations (and check-ins / check-outs).
  3. Registration of check-ins and check-outs in production management software.
  4. Working history display and order’s calculation.
  5. Managing orders and monitoring progress (not including warehouse).
It’s recommended for:
  • industries with simple products: metalworking, CNC, injection moulding, elastomers, carpentry, cardboard packaging, printing shops, tooling departments, other simple production and production-support processes (ex. plating process),
  • from 2-3 people at the production hall up to about 30 people.
 The example software: getprodio.com  (click here to get a free trial)

 production planning trial

2.2 Advanced MES-es with a possibility of accounting and inventory integration

This narrow group is dedicated to larger companies, which prefer to keep their accounting and inventory system or even a simple ERP (which doesn’t have as interesting production as ex. Comarch CDN XL).

Integration isn’t often as comfortable and lacking daily problems, as in case of unified ERP, but it’s possible to make some great savings. We get a good production management software, without a necessity of buying a whole accounting system.

The example software:
  • Online version of production management software Qcadoo MES
    Qcadoo MES - screen ze strony producenta
  • Advanced online version of MES OptiMES
Typical pricing – how much costs advanced production management software:
  • For SaaS as paid monthly subscription: from 1 200 zł PLN + about 6 – 10 tys. PLN implementation;
  • For offline systems from about 20 do 40 tys. PLN for implementation + 10 – 20% of this amount for annual licence;
  • Equipment: it requires a sophisticated network infrastructure.
Target:

Advanced calculations of product making, production scheduling with accounting for inventory and integration with accounting.

Functions:

  1. Everything, what a simple production management software has PLUS:
  2. Advanced planning, including machine calendar, employees competencies matrix, Gantt’s graphs, etc.;
  3. Advanced monitoring, including bottlenecks, downtime, and OEE factor;
  4. Calculations and offering (including margines and provision / mark-ups on department costs);
  5. Warehouse management (inventory documentation, disbursement methods and attributes in documentation);
  6. Integration with accounting and inventory systems.
It is recommended for:
  • companies, which would like to have a complete functionality of ERP, but wish to keep their present accounting and inventory software,
  • planners, who wish to use advanced planning functions, including automatic scheduling,
  • companies aware of the number of data necessary to provide for the system,
  • companies, which products are divided into small elements, where each of them needs a separate management.

2.3 Corporate MES systems (mainly as an addition to advanced ERP)

Are you surprised? It would be best if you weren’t, as it was mentioned earlier, that most ERP systems don’t reach a production hall and need additional extensions. That’s why MES additions were originally invented.

Machine integrated MES

The truly extended MES usually has a connection to machines to register their work and all working parameters in real-time (the example of simple and accessible for small companies solution can be a Polish production system – Żbik). A graphic below is from the producer’s website, which shows a production hall with several dozen machines and their updated status.

 

This is probably a dream of many owners of production companies. However, it’s worth considering, especially at the beginning, if the level of complexity and the cost of implementation will pay off. Those systems also prove to be the most useful in unified production processes – ex if you have several dozen similar machines and alike products.

Planning systems with automatic scheduling and the basics of artificial intelligence

The truly “all in one”. Form independent production planning to connect to machines, service works scheduling and complete registration of all processes at the production hall. Once combined with an ERP system (preferably with an automatic system based on robots), you have a complete factory 4.0 🙂

These marvels and wonders of technology can be introduced to small manufacture. When there’s a will, there’s away, and it’s not even about the costs, but the number of data required to provide for the system to give tips and operate, is immense. However, the strength of this solution allows ex. Car factories work successfully without hold-ups, despite thousands of configurations and elements.

It takes just 15 minutes to start using Prodio manufacturing software and schedule the first production order

4. ERP systems – basic „processors.”

This is one of the best marketing products in the IT history – software which can do practically anything, but in standard version offers almost nothing, because the company, which is responsible for implementation, has to make money. The best example is the companies that decided to change from Comarchow’s Optima and go through a few thousand zlotys worth implementing Comarchow’s ERP CDN XL. It turned out that some functions or reports are available in simpler software, and for the ERP, they have to be written on request.

Other examples of the most popular ERP systems for smaller companies include SAP Business One and Insert Navireo. 

What is a PRACTICAL difference between operating of ERP system and an accounting program?

It isn’t the access to production or human resources (this module you can buy as an addition to simple accounting software). Still, a basic ERP system usually doesn’t have any production module, and you have to buy it as an extra

The difference between accounting and inventory software and ERP is calculating material from the warehouse (which is called material demand). For example, if you produce a bed, which consists of a frame and a matterrace, the earlier mentioned CDN Optima, will show you the total number of frames booked, based on the number of beds ordered. However, it won’t use this information while making a purchase plan connected to the production process until CDN XL, from the same producer, will point it, but you have to spend tens of thousands before.

Please remember that practically none of the ERP-s reach the production hall, so it is not a standard feature.


The idea is that you buy a basic version of ERP and next upgrade or modify it to suit your needs better. Usually, you end up buying additional modules to get your ERP system work: 

  • The production module for ERP – enables creating of products technology and work planning;
  • MES registration module for production employees, where they can click completed works/operations to appear on the production plan;
  • CMMS  (managing maintenance, machine service, etc.);
  • WMS (warehouse managing system, operating on bar codes). 

To sum up, the newest ERP-s are sophisticated tools, where you buy a “foundation” and build on it a perfectly tailored system, adding as many “building blocks” as you need. If you wish to have an ERP for production, you have to search for ERP + MES.

The typical cost of ERP for a company with 35-50 people

  • Base and licenses: from 20 000 – 50 000 tys. PLN + on average 1 500 – 4 500 for each working station;
  • Adjusting cost and production additions: on average twice as much as the cost of licence;
  • Maintenance and updates: about 20% of the cost of the licence;
  • Safe budgeting:
    • the simplest solutions such as Modus – 35 – 40 tys. PLN,
    • market standard: 250 tys. PLN,
    • market leaders: 400 – 600 tys. PLN.

Production management software – be aware of traps 

Watch out for “free production management software” or “open source ERP.”

  • Free is usually only basic modules licences (such as ex. OpenOffice), any dedicated modules must be purchased at additional costs;
  • Independently installed systems usually don’t have any guarantee and technical support, and they might not be developed any further;
  • Imagine that possibly you managed to install some open source ERP, and there is another JPK, which you have no idea about;
  • Software implementation and adjusting it to your needs as well as maintenance are paid, and fees are very high – this is the “revenge” of free licence policy;
  • It turned out in total balance that “free” software is more expensive than the paid ones and involves higher uncertainty.

The smaller the company is, the faster it should move to a “cloud”, as sooner or later that’s the way all business will go 😉

  • Installing any software in your company, you have to realize, that in a few years time, you might have to start from scratch;
  • Practically speaking, for small companies, without IT department and advanced network, an online service is much safer than storage data at their premises.
  • The term “cloud” for production software shouldn’t scare you, because the data is on particular server in secure location (as it is in Prodio), it isn’t all over the Internet, as in other cloud services.

Integration with accounts and inventory module isn’t always worth doing.

As an entrepreneur, you strive to have work automated. You fight to eliminate dispensable procedures; you wish to pay once only and have everything in one place – this thinking is like grist to the mill of companies, which want to sell you the idea of “integration”.

Integration is great, but it requires precision, and the system should be tailor-made for the company.

Each waste and what will happen with it (to go to the warehouse or the trash), each technological change or different raw material used by an employee MUST BE ACCOUNTED FOR in the system. Otherwise, just after 2 months, it will be impossible to count your stock automatically calculated and based on production. No products can be taken without being physically ordered, and all actions must be put in the system (it will be blocked otherwise).

You might now think it’s great and that finally your small manufacture will be organized – but when there are really many orders. The machines can’t work because you didn’t enter all the necessary data into the system. You may go back to old good paper orders and leave this new system behind, although you spent on it several dozen.

Automatic planning – won’t pay itself off!

Gantt’s graph and a dream of one magic button setting a production plan is a topic of many talks between company owners.

Meanwhile, although there appeared many different programs, which promise to plan everything themselves, so far it is still necessary for the software to know before it starts planning process:

  • calendar of avaliability of production employees, time off work, their work presence,
  • matrix of competencies, to know who and in which scope can perform operation on which machine,
  • service and maintenance schedule,
  • perfectly prepared technology of product, including changeovers, with exact lead times, possible replacement by other machines, types of tools used for a particular machine
  • properly run warehouse and inventiry system and raw material- products allocation.

If you fail to provide any of the above parameters, you can forget about even the best of algorythms automating the production for you 🙂 The software in a small company should tip you on your machines occupancy and estimated lead time of production. And this is exactly what we wish you 🙂

Manufacturing software implementation – typical mistakes. 

Failed manufacturing software implementations are a taboo topic in the manufacturing world, often swept under the rug. Why do manufacturers fail?

Do you want to avoid these implementation mistakes?

1) Perfect theory

 You have an idea of your perfect manufacturing software and a list of potential problems and difficulties. Regardless of tips, we give you – reality will put all of them to the test the most effectively. So no more theory, start practising!

 2) Let’s start after the season ends 

 How much time and money must be wasted to find a few hours for constructive optimization finally? 

 3) All in one package

 There are small manufactures, which wish to invest in advanced production, inventory and accounting software. Ok, but remember that your flexibility will also be limited and your daily tasks hindered.   

 4) I don’t have my data because it’s in “the cloud”.

 It is a much better solution for small manufacturers to store all software data at the external server with an encrypted connection, simpler, cheaper, and more convenient than internal infrastructure.   

 5)  I can’t afford it…

 Is 5% a lot for you? Let’s say you employ 15 people and spend about 30 000 euros each month on their salaries. If you increase productivity by 5%, you are plus 15 636 euros in a year. You are right – you can’t afford to buy Prodio.

Proving wrong 5 popular myths about cloud-based manufacturing software.

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