Oracle NetSuite Manufacturing Implementation

Assessment & Blueprinting

• Conducted detailed business requirement workshops.
• Mapped "As-Is" and designed "To-Be" processes.

Implementation Scope

• Modules Implemented:
  • Manufacturing (BOM, Work Orders, Routing, Production Planning)
  • Inventory Management (Raw Materials, Work in Progress)
  • Procure-to-Pay(P2P)
  • Order-to-Cash(O2C)
  • Finance & Accounting
  • Integration with third party tools specific to glass manufacturing industry

Customization & Optimization

• Developed custom workflows for sales order creation, manufacturing routing, work in progress tracking, order management.
• Automated workflows for procurement using replenishment methods.
• Configured dashboards for plant managers & CFO.

Change Management & Training

• Onsite/remote training sessions for end users.
• Continuous support during go-live phase.
• Enhancements

Implementation

The successful implementation covers in-depth mapping of all the sales, manufacturing & accounting functions.

• Raw Materials: The raw material records were created with different units for purchase, sale, consumption & stock. These units of measure are added in the system to handle the conversions amongst all units.
• Procurement: The purchase order module has been deployed with custom functionality to order & receive raw material in multiple units of measure.
• Finished Goods Item Records: The finished goods were created in NetSuite in such a manner so as to generate dynamic bill of quantities based on information received in the sales order or quotation.
• Sales Order Creation: Client customers finalize their design requirements on a third-party software. The final design is sent to NetSuite in XML format. The file contains customer information, delivery dates & shipping addresses, finished goods data for quantities of raw materials & manufacturing processes. The received XML file is parsed by NetSuite intelligently to decipher the dynamic bill of quantities & calculate the exact square footage of glass. It also includes validation of data received prior to create a sales order automatically.
• Manufacturing Process: The process consists of multiple work centers producing glass with routings for glass cutting, processes like seaming, fabrication, heat treatment, insulation, polishing etc. The manufacturing schedule is prepared in a third-party software and information at each routing step is passed into NetSuite using API calls. All such requests are processed in NetSuite to create work orders, work order issue & work order completion.
• Work In Progress: The advanced manufacturing module of NetSuite is used to track raw material wise inventory at each routing step. The in-house manufacturing tracker sends information for each manufacturing step in sync with the operation completed in the shop floor. This also provides inventory value at each routing step.

  The main steps covered are listed below –

  • i. Work Order Creation: Work orders are automatically created at the first routing step. The script checks for available / back ordered inventory prior to work order creation. The system also validates for already created work orders, if any, for relevant action to be taken at the manufacturing end.
  • ii. Work Order Issue: NetSuite receives details of raw material used along with their quantities. Based on this information, material is automatically issued in NetSuite. The script checks for available / back ordered inventory prior to work order issue. The inventory is marked as ‘WIP’ at this stage.
  • iii. Inventory Transfer: Inventory is transferred between all manufacturing locations to complete the manufacturing. These transfers include raw material, semi-finished & finished goods movement. All such transfers are handled in NetSuite on the basis on information received from in-house manufacturing tracker software.
  • iv. Work Order Completion: Upon completion of last step of manufacturing routing, NetSuite receives information through API. Work Order Completion step is done at this stage & finished goods are assembled in NetSuite to increment the inventory. The ‘WIP’ is released at this stage.
• Sales Order Fulfilment: NetSuite receives dispatch information via API calls & sales orders are automatically fulfilled. This covers partial fulfilment along with generating packing slips.
• Invoice Creation: Invoice is automatically created for all fulfilled orders. The invoice is automatically emailed to the customer.
• Reports: Customized reports using workbook analytics for real time visibility of manufacturing operations.