Plan, produce and deliver: Managing high-volume plastics and packaging | Part 2 of 3
In Part 1, we explored how plastics manufacturers balance production efficiency with planning flexibility. Forecasts, production schedules and material requirements help determine what needs to be produced and when.
Creating a production plan, however, is only the beginning.
Once manufacturing starts, conditions on the factory floor can change. Machines experience downtime, priorities shift, materials may not arrive as expected, and manufacturing orders may need to be rescheduled. Managing production effectively involves more than a good plan. It requires visibility of what is happening as work progresses.
This is where connecting your ERP with a Manufacturing Execution System, or MES, can make a difference. ERP provides the production plan, while MES provides information about manufacturing activity as work progresses.
Moving from planning to execution
Once manufacturing begins, visibility of actual production activity becomes increasingly useful alongside the production plan.
ERP systems help manufacturers understand what should be produced, when it should be produced, and which materials will be required. This information supports scheduling, purchasing and inventory management.
Once manufacturing begins, the focus shifts from planning to execution. Timely information about machine activity and production progress adds useful context as work moves through the factory.
ERP helps manufacturers plan what should happen. MES provides visibility of what is happening. Together, they provide a more complete view from production planning through to day-to-day manufacturing activity.
Connecting the production plan to the factory floor
Connecting ERP with MES enables production requirements to be transferred to the factory floor. Rather than recreating schedules or manually re-entering information, production teams can work from the same manufacturing orders established during the planning process.
For plastics manufacturers, this means production teams can work from current manufacturing requirements while adjusting schedules as priorities, machine availability or production conditions change. Manufacturing orders, materials and routing information remain connected throughout the process rather than being managed separately.
The result is a more connected flow of information from production planning through to manufacturing activity.
How Abel ERP and AspectPL MES work together
AspectPL MES provides the link between Abel ERP and production equipment on the factory floor.
AspectPL provides visibility of manufacturing activity as production takes place. The system interfaces directly with factory-floor equipment, enabling work to be scheduled, monitored and adjusted throughout the manufacturing process.
Manufacturing orders can be transferred electronically from Abel ERP into AspectPL together with supporting production information. AspectPL manages shop-floor scheduling and provides visibility of manufacturing activity as production progresses, while production information is returned to Abel ERP.
Each system can fulfil its intended role without duplicating responsibility. AspectPL manages production execution and factory-floor activity, while Abel ERP manages inventory, materials, finished goods and broader business processes.
The result is an automated flow of information between planning and production, providing a more current view of manufacturing activity.
Visibility while production is underway
One of the advantages of MES is that production information becomes available while work is taking place.
Where production data is reviewed only at the end of a shift or after a manufacturing order has finished, opportunities to respond to issues such as machine slowdown, unplanned stoppage, material issues or emerging bottlenecks may have been reduced or lost.
MES helps provide visibility while production is underway. Production teams can monitor progress, identify issues earlier and make adjustments as work progresses.
For managers responsible for delivery performance, operational efficiency and customer commitments, MES supports faster and more informed decision-making.
Closing the gap between production and inventory
For many manufacturers, one of the ongoing challenges is understanding exactly what has been completed and what inventory is becoming available as production progresses.
As products move through manufacturing, information about completed quantities and production losses can be returned to the ERP system, making current production information available to planners, inventory managers and customer service teams.
The result is a clearer understanding of what has been produced, what materials have been consumed and what finished goods are becoming available to support customer demand. This makes current manufacturing information available to support inventory, purchasing and production decisions.
Manufacturers gain a more connected flow of information from planning and scheduling through production and inventory.
Looking ahead
Planning and production are only part of the story.
Once products have been manufactured, they must be recorded, stored, tracked and supplied to customers. Achieving this requires accurate inventory information and a clear understanding of what is available, what has been committed and what is still moving through production.
In Part 3, we explore how plastics manufacturers connect production, inventory and customer demand to manage stock availability, support customer fulfilment and improve visibility across the supply chain.
Learn more
Explore how Abel supports different industries and operating environments:
- Plastics, Packaging and High-Volume Manufacturing
- Food and Beverage Manufacturing
- Other Industries Supported by Abel ERP
Talk to Abel about connecting production planning, material requirements, manufacturing execution and inventory management to improve the flow of information from planning through to production.
