Faster and Cost Effective Composites Manufacturing with Dynamic Q2S ERP

Two of the few constants in composites manufacturing today are the pressures to decrease costs and increase the speed of production.

If you’re relying on systems not designed to manage highly customized products made with rapidly changing materials and production processes, you’re struggling to keep up.

The good news? Q2S ERP can help you reduce time to estimate and manufacture, manage practically infinite product variability and track and reduce material waste and other costs.

Whether your focus is bespoke and customized applications or high-volume composite parts, you benefit from the ability to readily and accurately estimate and produce the products or components your customers demand, when they demand them. The key capability?

A proven dynamic bill of materials generator.

 

Decrease complexity and time to production

Q2S ERP features a dynamic, multi-level and rules-based BOM generator built precisely for complex and mass customized product manufacturing.

All the possible combinations of height, length, thickness, purity, materials and resin types, shape and design can make accurately configuring and pricing orders complicated and time-consuming.

Without a system designed to manage dynamic products like yours, you can easily under or over price. You can estimate something your operation can’t make. Pricing can take so long you lose orders, especially if your staff is always waiting on your one or two configuration experts.

In integrated Q2S Configure Price Quote, the dynamic BOM generator converts your company’s engineering and production rules—complicated or simple—into a series of standard questions. By answering those questions, your staff can readily estimate and schedule new products for production.

The BOM rules ensure only manufacturable orders are quoted. You can build in the restrictions based on rating agencies, transportation, safety and equipment capabilities. Automatically.

This enables you to free engineering staff from the order entry process and allow your team to configure and price products, schedule jobs, monitor production, measure actual costs and more.

Even more significant, it dramatically reduces the time to estimate and release orders, especially if you’re trying to manage pricing and production in spreadsheets or with a SKU-based or single-level bill of materials generator. These are just not designed for make-to-order manufacturing.

Because Q2S CPQ simplifies the quote and order entry process, many companies allow customers to price and enter orders.

 

Reduce costs and downtime with Industry 4.0 initiatives

Can you schedule predictive maintenance tasks? Plan for tooling changeovers per product in your production schedule? Release enough production to reduce bottlenecks?

Q2S ERP with Production Workflow provides you with all these capabilities.

Recording your downtime is the first step in understanding how to reduce it. Understanding each machine’s downtime provides you information so you can make changes to increase the throughput within your plant.

Planning for scheduled downtime also allows you to schedule only possible work and reduce mid-stream bottlenecks.

You want to reduce time to price and fabricate, be more flexible, accurately track jobs and labor and reduce errors—and make it so product configuration and pricing can be done many people rather than just one or two.

The list of challenges for complex manufacturing goes on: inventory control, production scheduling, job tracking, identifying replacement parts and more.

 

Keep track

Do you have too much raw material tying up space? Only know inventory based on weekly cycle counts? Can’t tell the difference between stock and purchased-as-needed inventory, let alone keep track of it all?

Let Q2S ERP’s Materials Management tools help. Q2S differentiates stock inventory from purchased-as-needed inventory. When used with our Dynamic BOM, you can account for all required parts. Stock inventory is allocated and purchased-as-needed materials can automatically generate one or hundreds of purchase orders tied to a single job.

You also get real-time updates of WIP and finished goods using a perpetual inventory model. This level of integration creates visibility of what’s received (and more importantly, what has not been received) on a job-by-job and line-item-by-line-item basis, or across all active jobs.

 

Need a way to document processes?

Q2S ERP’s Production Workflow tools help you with sequencing work, material optimization and tracking progress to ensure on-time delivery.

You can go paperless or barcode everything. You can determine which product options get the most returns and easily create production pop-ups to alert the production floor when that option is included.

Proactively alert production if a step has been missed. Warn downstream stations of potential issues with an item. You can add supporting documentation for difficult steps.

 

Geneology

When a recall is required, do you sift through paper quality sheets for other jobs with the same raw material? Pay overtime to get it done?

In Q2S ERP, you assign a lot and serial number to inventory upon receipt, then record the lot and or serial number for consumption against jobs. For recalls and any other reason, you can instantly identify every job using the same lot number.

No more having to locate and search through stacks of paper. No more wondering if you’ve found them all. No more overtime.

Just expand from simple barcoding for job status to track and trace.

With Q2S, this is simple.

 

Connect the factory to your ERP

Tracking your progress allows the office to see product and job status without interrupting production.

Imagine being able to instantly tell a customer when they can expect their delivery. When both tools are in one system, it allows the person entering the order to automatically get the expected delivery date. The system can see the backlog, production workflow, capacity, delivery schedules and pre-plan.

 

Use one system to run your business and production

With machinery integration, Q2S MES’s Finite Capacity Planner and Production Scheduling can signal production bottlenecks before they happen. This allows scheduling to adjust and notify the customer before a delivery is late. You can also record machinery downtime for changing out parts or planned and unplanned maintenance activities.

When you plan for maintenance, capacity can accommodate and automatically move out work to the next shift or day.

 

Update a BOM in process

Changes happen on the floor. With Q2S ERP, your workers can edit quantities and swap materials within a BOM on the shop floor. This provides an accurate inventory without cycle counting and gives you accurate job costing. Plus you’ll be able to review expected versus actual material consumption for the job.

 

A dynamic and flexible solution

Q2S ERP offers a flexible solution for the evolving needs of composites fabricators—from sales to shipment and everything in between. Contact info@q2serp.com to schedule a discussion to see if we are a fit.