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BatchMaster

A formula based manufacturing application developed and implemented by BatchMaster Software.
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BatchMaster Software is 100% focused on developing and delivering process manufacturing software solutions to the food, chemical, nutraceutical and pharmaceutical industries.

BatchMaster Manufacturing is a formula based, process manufacturing application that supports R&D, formulation, packaging, costing, production, QC, QA, inventory, compliance, and traceability. Optional modules include sample management, planning (MRP), scheduling (MPS), warehousing, alert management, and EDI exchange. These capabilities enable companies to quickly streamline and scale up their operations, reduce costs and easily comply with today’s ever more stringent regulatory mandates.

BatchMaster Manufacturing runs with QuickBooks, Sage 100 & 300, Microsoft Dynamics GP and SAP Business One financials. Customers can purchase the on-premise application or run the application in the cloud, which offers a monthly subscription program. The application is highly flexible and scalable so it can be employed by manufacturers of all sizes, with many of our customers falling between $1 to $150 million in annual sales.

PRODUCT DEVELOPMENT

Create separate formulas and packaging specifications then analyze and dynamically adjust ingredients to meet physical, nutritional and cost property target values of intermediates and finished goods. Employ multi-level workflow approvals to monitor and expedite the approval of specifications.

PRODUCTION

Dynamically size, link and schedule batch jobs to quickly scale up production of intermediates and finished goods, including co-products and by-products. Employ auto inventory allocation and batch job adjustments to ensure batch job yields are achieved.

COSTING

Take into account the costs of raw materials and consumables as well as projected costs associated to fixed setup charges, scalable labor, tiered labor, markups, margins and losses to accurately estimate product costs during product development. Capture and auto calculate actuals (employ auto back flushing capabilities) and compare against estimates.

QUALITY

Leverage predefined libraries of inspection plans, checklists and QC tests to reduce rework and scrap, as well as employ adverse events, nonconformance and CAPA capabilities to support your continuous improvement initiative.

INVENTORY

Manage inventory variable characteristics and movements and gain a simultaneous view of an inventory’s weights, volumes and quantity in various units of measure.

COMPLIANCE

Generate compliant labels and documents (e.g. FDA, GHS / SDS) as well as audit reports to avoid fines and penalties

TRACEABILITY

Quickly track and trace suspect materials from receiving through shipping, shipping back to receiving, or anywhere within WIP in order to meet product traceability and recall mandates

MASTER PRODUCTION SCHEDULING

Generate and link the optimal number of dependent batch jobs required to meet current and forecasted demand using “what-if analysis” and graphical scheduling tools

MATERIALS REQUIREMENTS PLANNING

Employ planning dashboards to schedule purchase orders of required ingredients and packaging materials that will maintain optimum inventory levels and avoid shortages in production.

WAREHOUSING

Perform receiving, putaway, quality, inventory, order fulfillment tasks across multiple plants using smart phones and tablets. Mobile capabilities also support batch job and labor management.

REPORTING

Employ prebuilt reports and dashboards (e.g. trend analysis, BI) to make more informed decisions, faster.

Bills of Material

A large amount of the work need to be done in Process Manufacturing is in combining, mixing and preparing (e.g., heating, pressurizing) combinations of raw materials and intermediates. Towards the end of the production process is the packaging of your production output, into forms of use for customers, and often in a manner to accommodate Sales with promotional packaging. You need a great deal of versatility at this BOM stage, especially with consumer products, in which packaging provides the sizzle. Also, when providing materials to customers that they then remanufacture, your containers must be effective yet low in cost.

Capacity Planning

The fundamental basis for your decision-making is available capacity. Successful companies are those that carefully manage their capacity and make effective scheduling decisions. BatchMaster Enterprise Master Production Scheduling (MPS) provides rough-cut capacity planning, allowing you to compare projected resource requirements to available resources and process constraints. You can view effects on the utilization of key resources like labor, equipment or storage. Rough-cut capacity planning considers resource calendars, projected production line throughput rates and planned downtime to compare planned usage against projected available capacity. You will quickly spot idle capacity along with process bottlenecks to guide you in better balancing your resource utilization.

Compliance Reporting

Both your company’s reputation and the extent of its liability are dictated by your products’ compliance with specifications. You want to satisfy your consumers’ expectations without doing them any harm. The MSDS/Compliance module has powerful features that will automatically generate Material Safety Data Sheets in full compliance with the OSHA Hazard Communication Standard, SARA Title III, ANSI, and virtually all similar government reporting requirements. This module is designed to accommodate any required changes to meet new regulations immediately, without the need for a program update. The output MSDS is created as a Microsoft Word document.

Costing

The Costing module provides sophisticated, precise calculations based on all factors that affect product cost - including labor, overhead, loss, and more. It will reformulate mixtures to meet desired target costs, and generate detailed analyses of all types of cost-related data instantly! With BatchMaster, you can rely upon advanced tools, coupled with a disciplined methodology, to closely monitor and control your costs, without sacrificing quality.

Formulas

At the heart of your Product Development Lab is your ability to design and manage all your formulas. You need an audit trail on your experimentation to take the mystery out of success and make it repeatable. BatchMaster supports multi-level formulas and easy material substitutions. Experimentation with new formulas should be just as easy as the maintenance of your tried-and-true formulas. BatchMaster is formula- and not BOM-based, with ingredients added by prescribed proportions measured by either volume or weight.

Inventory Management

One of your highest priorities is managing your inventory effectively. Process manufacturers must accurately characterize all items they carry in inventory, keep track of their locations, maintain appropriate stock levels for all critical items, and be able to immediately supplement depleted stocks if a sales opportunity warrants. BatchMaster provides the controls and confidence necessary to reduce material inventory. Inventories can be valued using standard, average, LIFO, FIFO, or lot cost.

Laboratory

The Laboratory module brings the speed, power, and reliability of computerized formulation to your chemists and technicians. It reduces man-hours spent on tedious, error-prone manual calculations and delivers a wealth of useful information quickly and accurately. The module is flexible enough to meet your specific needs, no matter what types of products you manufacture. Raw material specifications and formula physical properties are user-definable, so BatchMaster can perform calculations exactly the way you are accustomed to using them.

Materials Planning

Master Production Scheduling (MPS) and Materials Requirements Planning (MRP) offer calendar creation, flexible demand ranges for forecasting, batch allocation, grouping of orders for processing together, and more. MPS enables strategic long-term planning to support projected sales. BatchMaster automates the placing of purchase and productionorders, so that an item planned in January can have its raw materials purchased in May and not enter production until June.

Production

The BatchMaster Production module was designed specifically to enhance operating efficiency of process manufacturers. Its powerful yet flexible features expedite scheduling, simplify batch sizing, and generate real-time information faster and easier than ever before. Being specially designed for the process manufacturing industry, BatchMaster Production leaves no gaps between the software and actual operations. BatchMaster Production’s Batch creation screen creates batches generating one or more final products. The batch can be assigned to a specific work center and scheduled to the day and time it is expected to run.

BatchMaster supports advanced batch models such as SuperBatch™ and Runs. SuperBatch allows for multiple steps of a single batch to be contained in a single SuperBatch object. Runs allows for large all day batches to be separated into individual executable pieces.

Purchasing

BatchMaster’s Purchasing functionality provides sophisticated management and organization to your purchasing operations. Purchase order processing simplifies item and vendor selection, reducing costly errors and increasing productivity while providing management with information required in making intelligent decisions. The entire purchasing process is supported, from securing quotations to placing orders to receiving and issuing vouchers for incoming materials.

BatchMaster interfaces seamlessly with accounting partner software, automatically posting inputs to Accounts Receivable, Accounts Payable, and General Ledger.

Quality Control

BatchMaster’s Quality Control facilities are versatile and offer support for every phase of your operations, from receipt and acceptance of raw materials, through production of intermediates, to inspections of finished goods before shipment to customers. QC can be provided for materials at purchase receipt, production or sales shipment. Consistent quality is what your customers expect.

Sales Order Entry

The Order Entry module provides tremendous versatility, control, and power over sales and order entry policies. Individual pricing strategies are clearly defined for each customer based on data from your own records. BatchMaster Sales Order Entry allows you to enter sales orders as you take them. Sales orders can be entered ad hoc or by using a sales template that was previously associated to the customer. Background information about the material, customer or previous transactions is easily obtained through the click of a button.

Orders can be entered using any defined weight or volume for the material. Printed forms such as the sales order acknowledgment or the invoice can have customer item names for the items.

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