Discrete Manufacturing & Process Manufacturing Software

Arxis Technology, Inc



 
Discrete Manufacturing & Process Manufacturing Software Arxis Technology Spotlight

Solutions: Process Manufacturing

Process Manufacturing describes a manufacturing process whereby materials are blended, cooked or mixed as opposed to assembled from discrete units. Some needs common to process manufacturing industries are:

  • Formulas (or recipes) are ratios, not static bills of material
  • Split bill of material (i.e., several products can share 1 formula, but have different packaging)
  • Flexibility with units of measure
  • Stringent quality control, with recall ability
  • Lot grading / attribute tracking and calculation

What is process (formula based) manufacturing and how does it differ from discrete manufacturing?
There are two basic categories of manufacturing software, discrete and process. Discrete manufacturing systems are generally designed around a bill of material containing whole, or discrete quantities of materials such as 1 axle, 2 tires, etc. Process manufacturing systems are driven by formulas such as 90% water, 5% flavoring, etc. Process manufacturers usually blend or mix materials rather than cutting, shaping, or assembling hard goods. Hybrid manufacturers combine process and discrete components. A good example would be a cosmetic company that mixes a batch of lip stick bulk and fills the bulk into a base container (process manufacturing), then assembles this into a finished product with a packaging and label bill of material (discrete manufacturing).

What vertical industries are best served by a process or hybrid manufacturing solution?
While many industries can benefit from process-centric solutions, here are a few key industries that commonly come up when dealing with process manufacturing:

  • SIC 20 - Food and beverage / Flavors
  • SIC 21 - Tobacco
  • SIC 2611 to 2631 - Paper / Pulp Mills
  • SIC 28 - Chemicals / Fragrances
  • SIC 29 - Petroleum
  • SIC 30 - Rubber / Plastics (usually hybrid)
  • SIC 32 - Stone / Clay / Glass (process-centric requirements; Concrete manufacturing is a good process manufacturing environment.)
  • SIC 33 - Primary Metals (sometimes hybrid; process-centric requirements)

What are some common issues that are specific to process and hybrid manufacturers?

  • Weight to Volume conversions with Specific Gravity calculations
  • Formulas (recipes) as opposed to Bill of Material
  • Production batch loss / gain (moisture / boiloff etc)
  • Full featured bi-directional lot recall (see Bioterrorism Act)
  • Elevated auditing and security requirements for formulas, production and regulations such as 21 CFR 11b
  • Full featured Quality Control (QC) and Certificate of Analysis (C of A) requirements
  • Customer specific QC and C of A requirements
  • Nutritional property calculations for produced goods
  • Lot strength and potency considerations in production
  • High decimal availability and precision in production
  • Co-products and by-products
  • FDA reporting requirements
  • Compliance reporting (HACCP, SARA, HAPS, MSDS etc)
  • Weight to Volume conversions with Specific Gravity calculations

For information on the solutions Arxis provides for process manufacturers, please visit our Sage 500 ERP and O2 Process Manufacturing pages or contact us at 866-624-2600. Also, for Food & Beverage Manufacturing Software please visit our Food & Beverage page.

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