BatchMaster Manufacturing

BatchMaster ERP Production Module

Manage all the mix, blend, fill, and assemble processes required to manufacture finished goods, including co-products and by-products, in a make-to-order, make-to-stock, and mixed-mode manufacturing environment with BatchMaster software.

Batch jobs are either manually or dynamically created, linked, and scheduled. Equipment scheduling, QC test, and special instructions execution are managed by the BatchMaster module. Raw material consumption is either manually recorded or automatically backflushed by the BatchMaster ERP system based on the finished goods yields and the batch job formulas. From inventory appropriation to finished goods completion, all quality-related transactions are captured and reported, including actual usage, labor costs, and yields.

Staff can adjust batch formulas, reassign equipment resources then monitor WIP to ensure that batch jobs meet their targets. Mandated execution of QC tests and special instructions can be performed by the staff via mobile devices with BatchMaster ERP manufacturing software.

Key Features:

• Dynamically re-adjust batch formulas and packaging bill of materials
• Link dependent batch jobs together
• Dynamically size and schedule batch jobs
• Assign equipment and labor to batch jobs
• Reserve inventory for specific batch job
• Prioritize and expedite batch jobs
• Rework intermediates and finished goods
• Auto-generate lot numbers for intermediates and finished goods
• Track and trace lot-controlled inventory throughout the process

What BatchMaster ERP Software can do for Process Manufacturing

Production’s dynamic batch job adjustment, sizing, and scheduling capabilities, as well as lot number generation, reduce your time spent on these activities. Together with mobile task execution of product movements into and out of production, QC test, and special instructions, you can quickly scale up.

Reduce future losses and streamline your process manufacturing operations by analyzing key statistics, including expected to actual output, expected to actual costs, yields, capacities, and labor efficiencies.

Bill of Materials Management Module with BatchMaster ERP Solution

BatchMaster software formulations manage the packaging specifications and added complexities of sub-assembles and top-level assemblies for finished goods. Bills of material consist of packaging and labeling materials, as well as special manufacturing instructions and costs. All raw material costs are rolled up into the sub-assembly and assembly final costs. Note that formulas used for producing intermediates and finished goods are managed in a separate module within the BatchMaster ERP software solution.

Bills of Material functions in the BatchMaster ERP system are used by product developers to create, analyze and approve finished goods’ packaging requirements. This same packaging functionality may be used again by staff whenever sub-assembles and top-level assemblies need to be adjusted to meet QC standards.

Key Features of BatchMaster Process Manufacturing ERP Software Solution:

• Establish a hierarchy of BOMs
• Designate multiple fill and packaging sizes
• Embed Raw Material Costs
• Embed Manufacturing Instructions
• Analyze and compare BOMs
• Manage multiple BOM versions
• Employ workflow approval processes

What BatchMaster ERP Bills of Material can do for Process Manufacturers

In the BatchMaster ERP system for Process Manufacturing, your formulas are managed separately from your packaging bills of material rather than together in a single finished goods specification. As a result, you can have multiple produce developers work on your formulas and packaging separately, reducing the overall number of specifications that need to be maintained.

The Bills of Materials features within the BatchMaster software reduce your time spent on tedious, error-prone manual calculations in designing, updating, and approving finished goods packaging to meet your customers’ specifications. And most importantly, staff will save time by linking a product formula to your various finished goods packaging configurations.

Formulation Management Module

Manage the formula-based specifications of intermediates and finished goods, including co-products and by-products, with BatchMaster software. The formula consists of ingredients, required QC steps, special manufacturing instructions, and costs. All ingredient weights, volumes, and physical and nutritional characteristics are rolled up into the formula.

Ingredients costs and labor costs are used to calculate the formula costs. Note that bills of material used for finished goods packaging or configurations are managed in a separate Bills of Material module.

The formulation feature is used by product developers to create, analyze and approve formulas. This same functionality may be used again by staff whenever batch formulas need to be adjusted to meet QC standards.

Key Features for Chemical Manufacturing Companies:

• Include items with theoretical characteristics
• Use physical and nutritional data from USDA and Genesis databases
• Embed Costs
• Embed Quality Control Tests
• Embed Manufacturing Instructions
• Define Losses
• Dynamically adjust ingredients to meet target characteristics
• Analyze and compare formulas
• Manage multiple formula versions
• Employ workflow approval processes

What Formulation can do for the Pharmaceutical Industries

In BatchMaster ERP manufacturing software, your formulas are managed separately from your packaging bills of material rather than together in a single finished goods specification. As a result, you can have multiple product developers work on your formulas and packaging separately, reducing the overall number of specifications that need to be maintained.

Reduce your time spent on tedious, error-prone manual calculations in designing, updating, and approving formulas to meet your customers’ specific needs. 

BatchMaster ERP Product Costing Module for Process Manufacturing

Finished goods costs take into consideration the costs defined in the formula and bill of materials during product development, as well as additional costs and loss factors encountered during production.

Static and variable costs embedded within formulas and bills of material contribute to the costs of finished goods. These costs consist of fixed setup charges, scalable labor, tiered labor, markups, margins, and losses that may be automatically adjusted based on the total batch size. Further costing analysis and approvals can be performed when adjustments are being made to the batch job formula. 

Costing allows Cost Accountants to approve newly developed and revised formulas and bills of materials during product development. to help increase efficiency and reduce costs

Key Features of BatchMaster ERP Process Manufacturing Software

• Perform​“what-if” cost scenarios
• Approve formula and bills of materials based on costs
• Compare the cost of finished goods in different packaging configurations
• Analyze expected vs. actual cost of finished goods

What Costing can do for Process Manufacturing

You can compare the actual cost against expected costs to determine which processes are to be streamlined and then standardized, as well as if any finished goods costs need to be updated in your financial system.

With tighter control over finished goods costs and prices, from the time of product development through batch production, you can achieve the highest margins for your process manufacturing company. 

Production Management Module with BatchMaster ERP System

The BatchMaster ERP process manufacturing software solutions functionalities were designed specifically to enhance the operating efficiency for process manufacturing. Advanced batch models such as SuperBatch™ and Runs are supported. SuperBatch™ allows for multiple steps of a single batch to be contained in a single SuperBatch™ object. Runs allow for large all-day batches to be separated into individual executable pieces. 

The BatchMaster enterprise resource planning​“Split Bill-of-Materials,” which separates the Formulation from the Packaging Bill-of-Materials, allows process manufacturers to make one large batch of material and fill it out into multiple different packaging sizes or even different brands from that one batch.

• Extensive Batch sizing options.
• Optional BOM and Material substitutions give Maximum flexibility to the manufacturing process.
• Full and Partial Closing allows for immediate shipment of urgent orders.

Quality Control Module

Quality capabilities are found throughout the production and distribution processes to ensure that raw materials to finished goods meet your corporate and customer’s strict quality standards. Establish standardized QC procedures that address the inspection of vendor-delivered goods, batch jobs in WIP, intermediate inventory in the warehouse, and finished goods ready for customer delivery.

Quality managers can establish a library of QC tests with BatchMaster ERP, which will be added to formulas and packaging bills of material specifications by product developers. On the production line, QC tests are presented to line personnel, who record the QC results, and based on the results, will make the appropriate adjustments to the batch job formulas. Receiving personnel will be presented, capture QC tests of received goods, and then disposition the goods based on the QC results.

Key Features for Process Manufacturers

• Define QC test accepted values, tolerance values, sample, and recount values 
• Mandate the execution of QC tasks in receiving and production
• Generate separate QC test documents
• Capture QC tests via mobile devices
• Analyze QC test results
• Generate customized Certificates of Analysis 

What Quality Control can do for Food Manufacturing

You can establish a library of standardized QC tests against intermediates and finished goods. Analyzing the QC test results will enable you to rank suppliers, identify and improve your current manufacturing processes, and identify and correct any out-of-tolerance pieces of equipment. Most importantly, by consistently meeting your high-quality standards, you can minimize customer chargebacks that impact your bottom line.

Samples Management Module

The Sample Management module within the BatchMaster ERP solution creates the formula and packaging specifications for new products requested by either internal or external sources. Sample development is an optional precursor process to the formulation and packaging bill of materials processes. Sample Management identifies the requestor, their profile, and specific product requirements and then tracks the progress of this new product from request to acceptance.

The Sample Management enterprise resource planning feature within the BatchMaster ERP solution is used by product developers to create, analyze and approve new formulas, packaging, and finished goods.

Key Features of BatchMaster Process Manufacturing ERP Software for the Food Manufacturing Business

• Define requestor profiles
• Define both formula and packaging items in a sample specification
• Track material, packaging, and R&D costs per sample
• Track all communications with customer contacts, including email capabilities 
• Items with theoretical characteristics
• Items that have physical and nutritional data from USDA and Genesis databases
• Embedded Costs
• Embedded Quality Control Tests
• Embedded Manufacturing Instructions
• Defined Losses
• Dynamically adjust ingredients to meet target characteristics
• Analyze and compare formulas
• Manage multiple formula versions
• Employ workflow approval processes

What Sample Management can do for Your Company

Sample Management is separate from the Formulation and Packaging Bills of Material Modules, which allows you or other product developers to focus just on creating new products rather than maintaining existing ones. By tracking all inside sales or customer requests, management gains greater insight into product trends.