Plastics and Rubber Manufacturing Software

ERP for Plastics and Rubber Industry – SYSPRO Business Solutions for Manufacturers

Technological revolutions such as Industry 4.0 and the digital economy, combined with ever-increasing regulation and environmental protectionism laws, have put the plastics and rubber industry at the epicentre of new-age manufacturing processes. The use of plastics and rubber products in modern society will continue to expand just as rapidly as organizations innovate. Advances in polymers, resins and additives, coupled with the industry’s move toward e-commerce, mass customization and even 3D printing, add up to increasing complexity for your business, along with the effects of improved quality requirements.

Evolving your manufacturing technologies, tools, processes, and practices will forever affect the design, development, and production continuum in this industry. Discover how SYSPRO ERP software can give you 360-degree insight across your business so you can make faster, better decisions, and meet your sustainability goals while you transform your operations.

7 key Plastics and Rubber Manufacturing challenges SYSPRO can help you resolve

300 MMT

The total global production of plastics amounts to
approximately 300 million metric tons annually.

source: statista.com

Accommodate variable end-products

Using SYSPRO’s co-products and manufacturing inspection functionality, you can easily cost and capture the receipt of multiple products of varying grades from jobs originally planned for single-grade items.
You can choose to apportion costs between components and co-products according to a percentage breakdown for total material, operation and sub-contract cost, or you can define percentages against specific operations and materials.
SYSPRO’s Work in Progress inspection system gives you the tools to record the inspection details of manufactured items and, depending on the results, select to receipt, scrap or rework quantities. Units in inspection are visible, but unavailable for use until accepted into stock. Within the inspection function, you can capture detailed records of counts, inspection, scrap, rework and stock receipts.
You can receipt inspection items as the original product to manufacture, or as a different product or products, which is useful for end-products of variable grade. Also, you can receipt items into a warehouse different than what was originally planned.

Ensure quality of raw materials

SYSPRO’s Quality Management System (QMS) enables product quality control by allowing the configuration of multiple measurement metrics, as well as inspection points per inventory item, such as length, chemical composition and hardness. This configuration includes the allowable tolerances for each metric and inspection frequency is configurable as required; for example, full, partial, periodic and random quantity sampling is supported.
Where a full QMS system is not required, quality checks may be implemented using the standard inspection facilities in the Work in Progress and Purchase Order modules. Purchased items can be flagged as requiring inspection so that during receipting, detailed records of counts, inspection, scrap, rejects and returns are recorded. Units in inspection are visible, but unavailable for use until accepted into stock. Similarly, SYSPRO’s Work in Progress inspection gives you the tools to inspect manufactured product quality and, depending on the results, select to receipt, scrap or rework quantities.

Manage the storage

SYSPRO provides a number of features to assist you in the control and management of hazardous and dangerous goods with regards to storage, packing and transportation.
Multi-warehouse functionality enables you to create virtual warehouses, and bins within warehouses, to represent separate dangerous goods storage areas for specific items.
The multimedia features enable you to, per stock code, link and display graphical, video and text information, such as material safety data sheets, dangerous goods safety marks, and safety gear icons. Operators then have access to view and print the information when required.
The system’s flexible custom form functionality enables you to capture dangerous and hazardous goods information per stock code.
SYSPRO also provides an extensive notes facility, the content of which you can configure to automatically print on certain documentation within the system. Notes include generic notes against all key fields, as well as special key field notes, such as the technical specification, dangerous goods handling, and inspection notes against inventory items.

Manage product and raw material traceability

Whether a compliance-critical requirement, or an analysis tool for continuous improvement strategies, the traceability of products from material origins through manufacture to final destination, is a key system requirement in many industries.
SYSPRO facilitates the recording of traceability and quality data on materials and products from purchasing through inspection, manufacturing, manufacturing inspection, stocking and sales. The recording of expiry and shelf-life information is also facilitated and powerful queries enable both upward and downward searches by stock code, lot number and transaction type.

Comply with environmental and safety regulations

Improve your capability to demonstrate compliance in your core processes, as well as implement a variety of control measures for stringent record-keeping to suit the level of vigilance required.
SYSPRO’s flexible features and integrated nature ensure rapid access to centralized compliance information across your business.

Optimize your Supply Chain

Leverage advanced forecasting and planning to more closely match supply with demand.
Ensure the right raw materials are in place for each job with advanced Material Requirements Planning (MRP).
Streamline purchasing by using Electronic Data Interchange (EDI) to trade with partners and value-added networks.
Track quality status, lot numbers, expiration dates and multiple units of measure.
Improve visibility of warehouse activity from receipt of goods through outbound shipping.
Use data to see production costs and requirements for each formula and component.

Streamline Production

Simplify planning and scheduling to maximize capacity.
Minimize bottlenecks with a real-time view of each step of the production process.
Manage Work in Process: gain control over scrap, yield and rework metrics.
Identify ways to sequence production more efficiently based on product characteristics.
Allocate inventory to orders on a first-expire-first-out (FEFO) basis to minimize waste.
Automate tracking of variances and defects.
Reduce lead times for faster delivery.

Simplify your operations with SYSPRO Plastics and Rubber Manufacturing Software

Technology integration – SYSPRO’s diverse modules allow for optimal and effective integration into any third-party system. SYSPRO allows for the connection of machines and other devices to digitize the factory (Industry 4.0) and gain competitive advantage.
Traceability – SYSPRO’s manufacturing traceability allows for ECC, inventory management, quick response to product recalls, search capabilities, vendor management, quality and lot tracking.
By-product and co-product management – being able to manage by-products and co-products results in less waste and fewer missed opportunities. Costs can be associated with certain co-products which gives a more transparent look into the profit and costs of each item. Manage by-products for those companies that produce by-products as a result of their manufacturing processes and who want to recycle, sell or use these by-products for some other value-added purpose, rather than write them off as unrecoverable scrap.
Ensure production quality and comply with ISO and SDS requirements.
Reduce costs and eliminate waste while remaining flexible and responsive with SYSPRO’s extensive toolset allowing you to better manage cost pressures across the value chain.

SYSPRO ERP at your finger tips

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Business Critical Solutions

Traceability

Industry-built to support your quality and safety systems, SYSPRO ERP offers a full traceability system which enables manufacturers to:

Track materials from receipt right through to delivery of the product to the customer, as well as at any level in between.
Rapidly identify, quarantine and retrieve potentially defective goods from customers.
Accelerate the time to completion of your product recalls.
Improve governance and drive compliance.
Continually test and improve your traceability system.
Remain compliant and meet regulatory reporting requirements.
Mitigate the risks associated with recall.

Work in progress

SYSPRO’s Work in Progress inspection system gives you the tools to record the inspection details of manufactured items and, depending on the results, select to receipt, scrap or rework quantities. Units in inspection are visible, but unavailable for use until accepted into stock. Within the inspection function, you can capture detailed records of counts, inspection, scrap, rework and stock receipts.
You can receipt inspection items as the original product to manufacture, or as a different product or products, which is useful for end-products of variable grade. Also, you can receipt items into a warehouse different than what was originally planned.

Bill of Materials

SYSPRO Bill of Materials (BOM) is designed to ensure your organization has complete control over the product structure.
The complete bill forms the foundation for material and capacity planning, shop floor control and costing and ensures that engineering, production, purchasing and order processing are utilizing the same information.
It allows you to facilitate accurate expected costs against which actual production costs can be tracked.
SYSPRO BOM provides a mechanism for configuring the manufacture of multiple items against a single bill of material, including those products that result from the manufacturing process but which are not included in demand planning. This is useful for companies that produce by-products as a result of their manufacturing processes and who want to recycle, sell or use these by-products for some other value-added purpose, rather than write them off as unrecoverable scrap.

Engineering Change Control (ECC)

Features enable the creation of user-defined Work-flows to control the product development process and ensure electronic sign-off. Transactional data is controlled through a paperless approval and authorization mechanism including ECC event triggers as defined by an organization.

Manufacturing Operations Management (MOM)

Allows for increased productivity, loss minimization and cost control. Optimize operational efficiencies through better workflow of core manufacturing activities: schedule, publish, collect, track, analyze and improve.

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Customer Success Story

Growth for TriStar Plastics began with a simple question for SYSPRO, “How can we make this better?”.

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