Control Centre Software

Control Center Overview

SG Systems V5 Control Center Software allows setup and control of key daily production and inventory control requirements. V5 Control Center Versions

Core modules include WMS (SO/PO Fulfillment), Recipe Formulation (BOM Setup), Production Planning & Scheduling, Finished Product Creation & Label Setup, SPC, Quality Assurance & Operator Controls.

The software provides full traceability (Forward_Traceability and Backward_Traceability) for companies requiring a single solution to track materials from receiving to shipping, including the respective batching and production processes.  It also acts as middleware for companies looking to extend ERP and accounting software functionality to include real time production floor data.

Software licenses & production hardware (touch screens, scales, bar code scanners, mobile computers etc)  communicates with a SQL database (Microsoft SQL or Oracle MySQL), providing connection to single and multi site operations.

Production Scheduling

The Production Planning & Scheduling module allows recipe batches, finished product and QC requirements to be scheduled centrally and executed by the respective shop floor terminals.

Batches are scheduled by quantity, mix size, production location and yield.  Multi-level formulations are automatically scheduled from the top down.  Scheduling finished product requirements (from sales orders) automatically calculates the number of batches required and mix size.

Finished products scheduling can take a different route.  Often finished products contain their own BOM (Bill of Materials) which is a combination of batches, assorted packaging items and post batch additions (seeds, dusting flour etc).

Recipe Formulation

Recipe Formulations contain unique codes and descriptions, versions, production locations, BOM (Bill of Materials with weights) and label printer / scale types.

Select commodities as steps in the formulation, enter the required quantities, production locations, tolerances & messages.  Based on the default bag weight, the system calculates whole or partial additions.  Batching Terminals guarantee weighing tolerances (+/- configurable).

Hierarchical software allows recipes to be used within other recipes (timestamped WIP), either completely or partially.  Such a process ensures multi-level traceability and controls across complex manufacturing processes.

Inventory Control / Cycle Counting

User definable commodities are setup in the system allowing type (ingredient, product, packaging or formulation), standard cost (or supplier specific), minimum levels and storage location to be defined.

Received inventory is lot controlled after completing a comprehensive receiving process (see WMS section) to ensure strict QA processes are followed.  Adjustments and withdrawals can be made easily using directed Cycle Count.

Inventory is consumed using Recipe Formulation Systems or Finished Product Terminals.  This auto reduction process provides perpetual inventory and minimizes the need to hold surplus quantities.  Automatic Bulk Ingredient FIFO is controlled using the Bulk Control Terminals.

Purchase & Sales Orders

Supplier PO and Customer SO can be entered into the SG Systems software directly, or imported from existing Accounting or ERP software (see ERP Integration section).

After entering the PO/SO, the execution is usually carried out using the mobile WMS hardware, allowing ease of mobility in the shipping and receiving areas.

The software allows editing of PO/SO from shipment back to inventory, providing a flexible solution for ‘high change’ environments, commonly found in companies with high order frequency and multiple SKU’s or a perishable nature.

QA / Safety & Allergen Control

Quality Control is key to all organizations.  The user friendly software allows a library of QA questions, responses and stages to be setup, for simple execution on the production floor.

QA Questions are first listed, then linked to specific commodities – this process ensures that the correct QA questions are prompted at the appropriate time with the associated commodity.

QA Events allow specific actions (inventory receiving, moving, adjusting, withdrawing, quarantine etc) to prompt for specific questions.  This functionality typically removes the need for manual QA paperwork.  The time stamping of responses also provides validation that the response is viable.

Operator Controls

Controlling Operator access is a critical part of any manufacturing execution system. Many permissions exist in the standard software, allowing you to define which person has access to specific functions (Such as system setup, languages & scheduling control).

Controls relate to Back Office functionality and also to specific floor tasks, such as WMS, Batching & Finished Product Creation.

Operator logins can be color coded, allowing high contrast production screens to display the selected color for rapid login identification at critical control points.