Analysis of Characteristics of Handicraft Industry

Handicraft production companies are typical discrete manufacturing companies. The production process of products is usually broken down into many processing tasks to complete. Each task only requires the company’s For a small part of capabilities and resources, enterprises generally build some production organizations (departments, workshops, groups, etc.) with similar functional materials and equipment according to space and administrative management. In each department, workpieces are processed from one work center to another for different types of operations.

Compared with industries with high automation procedures such as machinery, chemicals, and electronics, handicraft manufacturing companies have the following obvious characteristics:

ØA single product is relatively simple, but the product variety There are many, and a large number of new samples need to be developed according to market trends every year;

Ø Taking order production as the main business method, when customers place orders, they often involve changing samples, packaging, accessories, and assembly methods. and other personalized needs;

ØAn order often involves multiple varieties, and there are many single small varieties;

ØThe entire production process is mainly manual operation by workers, with automated machinery and equipment There is less use of it, and production capacity largely depends on the number and proficiency of workers;

ØThere are many orders online in each workshop at the same time, and it is difficult to collect raw and auxiliary materials according to the order;

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Ø Basically, the salary management method is based on piece-rate wages, and some time-based wages are also used;

The main problems faced by handicraft production enterprises

Ø Sample data is scattered and missing

For handicraft companies, sample data is the most basic and one of the most important information, because it is an important basis for the entire enterprise's production planning, material requirements and procurement. It also plays an important role in tracking customer quotations and sample delivery. However, due to the large number of samples and frequent customer requests for sample changes, most companies currently have such a problem. The data on molds, blanks, process costs, raw/auxiliary materials, packaging, and accessories in the sample files are scattered in various places. In the hands of departments or personnel, it often results in incomplete sample data, untimely updates, or errors when the data is transferred from the business process to the production department;

ØIt is difficult to formulate production plans, with low efficiency and poor results

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Because there are many varieties of goods in the order, many customers have personalized requirements, and the product production process involves multiple processes, it takes a lot of time for production managers to just decompose the specific production tasks of the order, and it is difficult to have the energy to do it. Comprehensive consideration of the balance of production capacity and production progress between each product number and each process makes it difficult to reasonably arrange the production plan. This phenomenon, in turn, often leads to frequent rushes and a vicious cycle;

Due to the large number of simultaneous production orders, the wide variety of product numbers in a single order, and the many processes involved in the production process, it is difficult to grasp the actual production in a timely manner relying on manual management methods. Progress, it often happens that a certain item number cannot be delivered in time until it is shipped;

ØThe salary calculation workload is heavy and the efficiency is low

In handicraft companies, generally There are many employees, and there are many types of products and product production processes produced at the same time, and there are often orders for production across months. Therefore, piece rate wages are very labor-intensive and time-consuming work, and it is difficult to ensure the accuracy of the data and it is difficult to achieve good results. There may be wage black holes in local control of over-production registration, intentional transfer of output of resigned employees, etc.;

ØDifficulties in cost analysis

The actual production process of handicrafts is full of variables, from mold opening methods, Starting from the actual quantity of molds put in, to the actual practices of each process, rework, damage, make-up, labor price adjustment, etc., the data of the actual production process are often inconsistent with the data during sample development and design, raw/auxiliary materials, packaging materials, accessories The actual purchase price may also change. In addition, semi-finished products and in-process products remain in various workshops and processes. Without the help of systematic data analysis and tracking methods, it is almost impossible to calculate the production efficiency of each production department. It is impossible to calculate Output the actual consumption cost of each order and each item number;

Yixing Crafts ERP Solution

Taking into account the key points of production control of crafts of different materials, the product data characteristics are quite different, we Over the years, the company has customized multiple successful cases for different industries. The industry scope involves the resin handicraft industry, daily/craft ceramics industry, cloth art industry, toy industry, wood products industry, etc., especially the Yixing resin industry ERP System, Yixing ceramic industry ERP system has been successfully used by many well-known companies in the industry, laying a good foundation for the long-term sustainable development of the company.

Overview of the main functions and features of the Yixing resin industry ERP system

Product BOM management

1. Package mode management: Maintain the sub-item number combination of the package number

2. Green body structure management: maintain the green body splitting method of the product, support the same green body with different colors, and support formula management;

3. Mold management: maintain the mold information of the product, Including all mold-related data such as the mold opening method, number of holes, order, silicone dosage, etc.;

4. Process price management: subdivided into each body, and maintaining all process costs of each body Price data supports process material management, and supports packaging and assembly labor price accounting;

Working hours can be deduced based on labor prices, or labor prices can be calculated based on labor hours;

5. Cost accounting :

1) Mold cost: Calculate the material cost comprehensively and accurately based on the amount of silica gel, plaster materials and various auxiliary materials. Combined with the mold opening price, the mold cost is calculated. According to the number of uses, the cost is calculated per unit. Mold cost of the green body;

2) Slurry cost: According to the formula ratio, calculate the amount and cost of resin, gypsum amount and cost, filler amount and cost, and also calculate the cost of red and white additives; < /p>

3) Labor cost: including grouting, grinding, trimming, etc. in the molding stage, painting, eye paint, spray paint, varnish, etc. in the painting stage, and assembly and packaging in the packaging stage. Cost;

4) Packaging cost: actuarially calculate the cost of inner box, middle box, outer box, as well as the cost of protective materials such as bubble bags and Styrofoam, egg trays, partitions, sealing glue, packing tape, etc. For the cost of packaging auxiliary materials, calculate the cost of single-piece packaging based on the whole box packaging cost and packaging rate;

5) Cost of accessories: Calculate the cost of accessories based on the usage of product accessories;

6 ) Other costs: Calculate management fees, taxes and other additional costs;

Production plan management

According to the personalized needs of customers when placing orders, automatically generate production task orders based on the order BOM ;

Combined with the inventory quantities of white stock, color stock, etc., the automatically generated production task list specifies the number of mold openings, the production quantity of the green body, the material formula of the green body, and the various processes required for the green body. All processing information such as the quantity and labor price of the process, the production task order can be directly issued to each workshop to arrange production;

Combined with the production capacity analysis, reasonably arrange the online time of the process, and provide reminders for bottleneck processes;

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Workshop operation management

The carefully designed production registration module, with a scale of 2,000 workers, requires only one dedicated entry person to register the production daily reports of all processes;

Built-in over-production reminder function when registering daily output;

Multiple workshop picking management modes, supporting the function of picking materials by order or combined picking, and supporting the function of separate deduction of materials;

Supports individual piece counting and assembly line piece counting;

Built-in damage replenishment management module;

Semi-finished products warehousing and receipt management;

Production progress tracking

Provides multiple ways of real-time query of order production progress, which can be as detailed as order-goods number-blank body-process to fully understand the production progress details;

Production balance analysis, comprehensive analysis of each order within the order Production progress balance data between product numbers and between each process within the product number;

Production progress warning reminder, based on the order's shipment plan, automatically reminds product numbers that may be lagging behind;

Order Procurement Management

Automatically conduct purchase quantity analysis of packaging materials and accessories based on order variety, quantity, and personalized needs for packaging and accessories;

Analysis results based on purchase quantity , combined with material classification and supplier type, automatically generate purchase orders corresponding to each supplier;

Analysis of the actual production cost of the order

The actual production cost takes into account the damage replenishment situation, the original /The actual purchase price of auxiliary materials, as well as the adjustment of process labor prices, the actual placement of molds, etc., automatically calculate the actual production cost of each order;

Salary accounting management

The system automatically extracts personal piecework registration data, assembly line registration data (including assembly line scoring, work point registration), personal material requisition data (including various requisition records, auxiliary material requisition records), hourly wage registration data, employee reward and punishment records, and Data provided by the administrative department such as attendance, accommodation, dining, etc., combined with calculation rules, automatically calculate the piece-rate wages of all workers;

Overview of the main functional features of the Yixing Ceramics Industry ERP system

And others Compared with the handicraft industry, due to the high-temperature firing process, it is more difficult to control the production process of ceramics. The current level of information management of ceramic production enterprises, especially in terms of refined control of the production process, is still generally on the low side. Low cost, lack of cost control means, and cost waste in all aspects of the production process are difficult to eradicate.

Through full cooperation with Chaozhou Yuri Ceramics Manufacturing Co., Ltd., our company has successfully developed an ERP management system for the ceramic industry. This system has raised the production management level of Yuri Company to an unprecedented new level, achieving Through careful management of all aspects of the entire production process, various losses and wastes are clearly and systematically controlled, and production efficiency is steadily improved.

Yuri Company is China's leading enterprise of craft daily-use porcelain. It is famous for its product development capabilities. It develops a large number of wares and patterns every year. The complexity of the process is very typical. The products are medium and high temperature. Mainly, the products often have carved and flower designs, the molding methods include grouting, pressure, rolling, and the flower surface decoration includes baked flowers, color painting, gold, underglaze and other methods.

The operators of Yuri Company have a full understanding of computer information management. In the 1990s, they began to gradually use computer systems to manage the production process. However, due to the complexity of the process, the production cost has been difficult to achieve. Effective control, although simple production management software can achieve timely statistics of some production data, it cannot fundamentally solve the cost control problem. During this period, the company also used an ERP product from a well-known domestic company. However, due to the particularity of the industry, despite the full cooperation of all the company's employees, it came to nothing after nearly a year of hard work. After learning from the experience, Yuri Company approached YiXing Company to develop a complete ERP management system for it. YiXing developers lived up to their expectations and finally provided Yuri Company with a highly successful ERP management system, which solved the cost control that had troubled the company for many years. problem.

Yixing Ceramics ERP Features:

1. Solve the problem of reasonable fabric production for orders: How to accurately calculate the production quantity of adobe fabric based on the order quantity is the first thing that ceramic manufacturers must solve The problem is that too much blank will definitely cause waste, and if there is not enough blank, it will easily lead to the quantity of finished products not being guaranteed. This is a dilemma. Yixing Ceramics ERP starts from the yield analysis of each link, comprehensively considers the factors of the device type, firing temperature, and decorative requirements, and uses statistical principles to collect and analyze historical production process data, so that it can basically accurately determine the order of fabric production. Suggestions on the number of raw blanks are given, thereby reducing costs at the source;

2. Realizing the analysis and control of firing costs: Among the costs of porcelain, firing costs account for To a high extent, how to reduce firing costs is an important factor in controlling production costs. In the firing cost, different kiln equipment and firing temperature curves have a great impact on the firing cost. Another factor that can be improved is the reasonable kiln density. In the case of multiple types of vessels being mixed-fired in one kiln at the same time, this factor is most likely to cause fluctuations in firing costs due to the large human component.

Yixing Ceramics ERP provides kiln installation data monitoring function, which can effectively avoid unreasonable kiln installation density and provide a second step to reduce costs;

3. Use the defect analysis system to find avoidable defects factors, and accurately distinguish responsibility for defects, thereby systematically controlling waste caused by artificial factors, and promptly analyzing defects caused by material factors such as porcelain mud and glaze water;

There are many factors that cause porcelain defects, but Many of these factors can be effectively avoided, such as promptly discovering unqualified adobe bricks during billet inspection, do not transfer the green bricks that will definitely burn out to the kiln workshop for firing, check the quality of the clay bricks after biscuit firing, and promptly Clean and repair the defects of biscuit firing. Do not bring the defects of bisque firing into the glaze firing stage. Kiln workers should clean various kiln furniture in time and keep the kiln furniture clean to reduce slag defects;

Reduce defects caused by artificial factors. A prerequisite is that the responsible person can be accurately traced. It is through this that the defect analysis system in Yixing Ceramics ERP can greatly reduce the defects of human factors, thereby laying a solid foundation for cost control; < /p>

4. Workshop benefit accounting system. Yixing Ceramics ERP can accurately calculate the monthly production benefits of each department. The accounting granularity reaches the component level. The accounting method distinguishes between products in progress and finished products. The accounting content covers all costs. project, the accounting accuracy has reached a level that can be truly used for performance appraisal, making the system reach a level that can effectively mobilize the enthusiasm of managers. This is also the core value of Yixing Ceramics ERP. Currently, there is no other ceramic management software in China It can reach such heights;

5. Other functional features of Yixing Ceramics ERP:

1) The built-in fuel cost calculation formula can basically accurately predict the conditions in various kiln environments. , the fuel cost of porcelain at various firing temperatures;

2) The built-in decal paper cost calculation function can calculate the decal paper cost of various colored porcelain products with full flowers or multiple flowers;

3) The mold cost calculation function can automatically calculate the processing labor and material costs of the mold according to the mold type;

4) Track all products from the beginning of molding to packaging and warehousing. In the process of processing, quality inspection and handover, the current status of all products online can be grasped in real time;

5) Barcode scanning technology is used to realize the rapid and accurate registration function of various data, and the workshop supervisor issues it to employees through the system. After the barcode processing task order is completed, the data will be collected into the system in real time by scanning the bar. The efficiency, accuracy, and real-time nature of data entry are fully guaranteed, thus providing guarantee for various data analysis and progress monitoring; This is also an important basis for the successful application of the system. If the data entry workload is heavy, the efficiency is low, and the accuracy cannot be guaranteed, it will be difficult for the system to function;