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In last week’s blog, we looked at quality assurance (QA) best practices for manufacturers. In that post, we touched on the fact that many use the terms quality assurance and quality control (QC) interchangeably, even though they represent different functions in the overall quality management process. As we noted then, a distinction between the two terms is that quality assurance is process-focused and quality control is product-focused. Another way to view the distinction is that QC is designed to discover flaws or defects in a product or process and QA investigates the root causes that led to those flaws and seeks to correct them. Read More

Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.

Quality Management is a rigorous methodology employed by a manufacturing company to ensure that the quality of its products is consistent. Two essential components of quality management are Quality Assurance (QA) and Quality Control (QC), which are often used interchangeably, even though there are distinct differences between the two. Read More

Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.

In previous articles we introduced Bills of Materials (BOM) and Material Requirements Planning (MRP), two legs of the inventory planning tripod. The third is the Master Production Schedule (MPS). As the name implies the MPS decides what products are manufactured and when. The required raw materials are then identified by the finished goods BOM, the data from which is then integrated with current inventory data to create the MRP for raw materials procurement. Read More

Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.

MRP – A Brief Background

While the roots of Material Requirements Planning (MRP) can be traced all the way back to the 1940s and 1950s, it was in the 1970s, with the emergence of increasingly powerful mainframe and mini computers that MRP-focused systems began to appear. These early MRP systems integrated bill of materials and inventory data with master production scheduling functionality to help calculate materials requirements for finished products. Read More

Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.

In our last post, we focused on the advantages of automated BOMs vs. manual spreadsheet-based systems. Today, we’re going to drill down a little further into types of BOM’s so that you have a better understanding of some of the available options.

While there are many types of BOM’s, some of which are unique to specific business sectors, two types stand out as the most common – manufacturing and engineering.

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Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.

A bill of materials (BOM) is a list of the raw materials, assemblies, sub-assemblies, components, sub-components and associated quantities plus labor and equipment needed to complete the job.

The BOM also requires quality control over each step in the process to ensure that no defective or substandard components find their way into the final product. If that happens, they must be replaced or modified to meet the specified standard.

Spreadsheets and Manual Processes Just Don’t Cut it Any More

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Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.

Cycle counting is an efficient and cost-effective way to ensure ongoing accuracy of your inventory counts and valuation. Usually, staff will perform cycle counts on a predetermined schedule, often weekly or monthly, and count a subset of the entire inventory in a specific area of the warehouse. Once these partial counts have covered the entire inventory, the cycle-counting process starts over.

Fix The Problem Before it Escalates

If any discrepancies are uncovered between the actual counts and what is reported in your ERP system Read More

Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.

Any small- to mid-size manufacturing business knows that effective inventory management is critical to success. With inventory tying up working capital stock turn is paramount. In addition non-turning stock takes up valuable space, may become outdated or obsolete and there is always a danger of shrinkage. It is critical to put in place inventory management best practices.

Manual Processes No Longer Work

One of the most common barriers to effective and accurate inventory management is Read More

Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.

The cloud has permeated nearly every sector of business and manufacturing is certainly no exception. The reasons are many for this transformation but one in particular is that Cloud ROI might just be too good to resist.

In the pre-cloud days, we lived in a time of expensive and labor-intensive, on-premise ERP systems that required extensive infrastructure and staff to maintain. Hardware and software needed constant upgrading as they became obsolete and legacy systems often contained customizations that were difficult to upgrade and to integrate with third-party add-ons. Read More

Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.

Procurement automation can reduce the cost of purchase order requisition, submittal and approval by up to 75% and invoice processing costs by up to 90%.

According to the American Productivity & Quality Center (APQC) companies using procurement automation receive deliveries two days faster on average than those who don’t. Read More

Allan Lessing
Seasoned professional in enterprise business solutions – aligning for success – strategic, tactical and execution with ‘hands on experience’. Making it happen – from business process optimization through implementation to post implementation excellence.