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FactoryMaster

A web-based multi-module management system designed by FactoryMaster for manufacturing companies.
Questions about FactoryMaster? Call (800) 827-1151 and talk to a software expert now.

FactoryMaster is a cost effective manufacturing software solution that will help your organization utilize the latest technology to assist in the planning and day-to-day operation of your company’s commercial and production processes, covering all aspects of the business in one package.

We are so confident that our manufacturing software will help you improve your business that we will happily introduce you to organizations that have achieved significant improvement in many aspects of their business such as, reducing lead times, increasing profitability and productivity, improving on-time delivery performance, reducing costs and overheads, improved cashflow by reducing WIP for stock holding, shop floor planning and documentation, purchasing (including material requirement planning) and job costing. It is important to know what is going on in real time and as such all costs are monitored real time so you don’t have to wait until it is too late to find out whether a job is profitable or has an unexpected margin.

Over the past year, one of our manufacturing software customers has achieved 20% growth in business while reducing arrears and overtime to a negligible level. They are also being hailed by a well known Aerospace manufacturer as one of their very few suppliers to respond satisfactorily to their adherence and delivery demands.

The best part is that this system is probably one of the most inexpensive yet most fully featured systems on the market. Developed over the last 12 years it is fully supported in each country it is sold by teams dedicated to providing Engineering focused Manufacturing Systems.

FactoryMaster is available on a single-user or multi-user platform with experienced training and support services available, ensuring success for your Sales, Production, Quality, Purchase and Finance teams who will all reap benefits from the system.

Configurator

The configurator is an advanced module that allows manufacturers of custom made products built to a size and dimension specification (e.g. windows, doors, kitchen countertops) to provide estimates and orders based on a specific configuration.

It allows the manufacturer to maintain just one bill of materials and manufacturing route. Upon order entry dimensions and sizes are requested. FactoryMaster will then calculate a tailored bill of materials as well as a tailored work order for the fulfilment of this order with no further work required by the user.

FactoryMaster also allows you to create quotes for work for configured item.

This functionality can have a significant impact upon the time it takes for work to be quoted and built within a system.

This type of module is a good example of how FactoryMaster can add extensive extra functionality into its core product without invalidating upgrade paths for customers.

Customization

FactoryMaster has extensive experience in creating ad hoc or custom functionality that is specific for a particular manufacturing technique or particular to a way an organization operates.

When FactoryMaster develop this extra functionality it is contained within the main FactoryMaster product so that the customer who has asked for the custom functionality does not fall outside of the upgrade path of the core product, so as the product changes and is enhanced you can take these changes without worrying about the cost and expense of adding your specific functionality into the solution again.

Other solution providers cannot offer this level of tailoring while maintaining and ensuring an upgrade path.

Estimating

Sales Quotes can be very quickly generated from a blank quote, a template or a previous quote for the same or similar part.

Simple estimates for resale or make to stock parts can be applied from list prices or calculated based on list price discounts that vary according to product, customer and/or quantity categories.

Complicated estimates for unique, one-off or make-to-order parts are just as simple and can be created on the fly or copied from existing BOM and routing records that, in turn, can be appended or modified to suit the current estimates requirements. If applicable, quantity discounts can be applied in the price build-up calculation for an assembly.

Routing labor and machine costs are automatically rolled up using the current standard operation times for each work center together with any outside processes. The user has the option of selecting the standard rate per hour currently defined for that resource - or you can override with a specific rate if desired.

Once time and material costs have been identified, selling prices based on a user defined margin can be applied to individual parts or individual margins can be applied to specific product categories within the BOM structure and automatically recalculated. The resulting price estimates can either be accepted or overridden with a more commercially suitable price.

Once time and material costs have been identified, selling prices based on a user defined margin can be applied to individual parts or individual margins can be applied to specific product categories within the BOM structure and automatically recalculated. The resulting price estimates can either be accepted or overridden with a more commercially suitable price.

Inventory

FactoryMaster provides full control over both raw material and finished goods inventory

Against each size of a particular raw material the total quantity on hand, available, on order and allocated is visible. Drilling down into this data provides a view to the individual batches and their respective supplier, purchase date, cost, cast number, release note number, quantity and number of lengths/sheets (by stores Location).

All standard types of stock movements (e.g. goods receipts, goods issued, adjustments, etc.) are catered for.

Future demand, by week or month, is calculated (via the M.R.P. report) from the forward order demand - expanded for Assemblies and taking into account manufacturing and purchase lead times to facilitate the necessary forward ordering of material to satisfy future demand.

Material traceability and costing to work orders is dynamically generated as material is booked out of stores against a work order.

Job Costing

Most companies are aware of whether they made a profit or loss for any particular month but often do not know how profitable individual jobs were or how profitable individual customers are compared one with another.

Often companies quote work and monitor income on a hour, but this must be recognized as a potentially dangerous practice where an unskilled laborer with a file doing some bench work is valued.

Rather than monitoring income on a global rate per hour per person, FactoryMaster enables a variety of easy to capture information to be organized automatically into a variety analyses.

The above procedure is considerably simplified as manufacturing instructions are automatically created from the quotation. These manufacturing instructions inherit all relevant attributes of the quotation but may then be expanded for actual production use (e.g. detailed manufacturing Instructions may be added for some operations).

All manufacturing instructions are associated with a specific drawing issue release for the part and these issue numbers are checked between manufacturing instructions, quotation, customer order and drawing register to ensure that route cards can only be produced where all Issues agree.

Job costing inquiries and reports are produced by job, part number, customer and accounting month.

Job costing and time comparisons between original quotation, manufacturing instruction plan and actuals are also available.

In addition, all time costed data is also captured against each resource so that a picture can be built up of the relative earning capacity (and profitability) of individual machines along with their actual earning hours. Information which, after a few months, could be used to adjust the available hours percentage for individual machines and processes on the resource file which in turn help make scheduling more accurate.

Manufacturing

Manufacturing instructions comprise the individual operation details of set-up time, operation/cycle time and lead time (for sub-contract processes) associated to the various resource codes that define the machines and processes provided by your company and its associated sub-contractors.

In addition to the standard resource descriptions (e.g. CNC milling, drilling, bench/assembly, etc.) the planner may also specify more detailed operation by operation instructions that will appear alongside the operation when the route card is printed. In the case of sub-contract operations, these detailed operation instructions are automatically reproduced on the relevant sub-contract purchase orders as are the associated batch prices which are also brought forward from the manufacturing instruction database.

Once manufacturing instructions are available, route cards may be printed for that part in either stand-alone format or via the work order and scheduling modules which will enable the Route Card to automatically reflect the Customer, Quantity, Due Date, Works Order Number, etc. All printed Route Cards have the Works Order Number printed in a Bar Code format to facilitate the Shop Floor Data Capture options available within FactoryMaster.

When utilized in conjunction with the estimating module the above procedure is simplified as manufacturing instructions are created automatically from the quotation. These manufacturing instructions inherit all relevant attributes of the quotation and may then be expanded for actual production use (e.g. detailed manufacturing instructions may be added for some operations).

All manufacturing instructions are associated with a specific drawing issue release for the part and these issue numbers are validated between manufacturing instructions, quotation, customer order and drawing register to ensure that route cards can only be produced where all Issues agree.

As well as the manufacturing instructions, it is also possible to record details of an associated data card reference, operator self-inspection check list, CNC program number or even to embed a stage drawing, digital photograph or digital video clip within each manufacturing stage.

MRP

The MRP module has become one of the most powerful features of FactoryMaster, providing substantial savings in planning time and effort, whilst ensuring that works orders and their associated material and component requirements are raised / ordered in a timely manner.

Purchasing

FactoryMaster contains powerful tools to make the raising and tracking of purchase orders simple.

Purchase Orders are raised under various categories to facilitate the easy recording of relevant details - for example:

  • Raw material - by specification, form, size or weight
  • Bought-in parts
  • Heat treatment specifications
  • Paint specifications
  • Sub-contract operations
  • Carbide tips
  • Consumable items

As many purchase categories as required can be created. Multiple batch prices are be recorded for any number of potential suppliers with a preferred status indicating the default supplier. Where appropriate, items can be associated to a specific Part or Drawing Number.

Sub-contract orders are particularly easy to raise as (when used in conjunction with the Works Order module) their technical content is automatically extracted from the relevant operation detail stored within the Manufacturing Instructions. The system can also generate Release Notes to accompany items sent away for sub-contract work to ensure full batch traceability.

Each item on a Purchase Order can be allocated to an existing Works Order so that the costs can be booked directly to the job upon receipt.

Booking costs to a job at the time of receipt allows the system to calculate an almost perfect costing without having to wait for any late invoices to arrive from your suppliers. However, the included Invoice Matching facility allows the user to compare the prices invoiced with those on the original purchase order and to adjust any discrepancies found.

A number of Expedite and Overdue Reporting options are available to chase outstanding purchase orders, including an Expedite Report which can be emailed to your suppliers requesting confirmation of delivery dates for each outstanding item.

The system also maintains comprehensive Supplier Delivery & Quality Performance Statistics to assist your Quality Department in ranking individual Suppliers against the categories of Product or Service they have been approved to supply.

Sales

FactoryMaster sales module provides extensive functionality for product configuration, quoting, and order entry.

The sales order allows multiple parts to be listed against the one customer order number. A delivery schedule based on quantity and date is entered for each Part.

Changes in delivery schedule easily be updated - either manually or via external sources such as email, E.D.I., XML etc.

Prices are automatically allocated against each delivery schedule quantity via the contract reviewed batch prices locked into each order which are entered (either manually or via direct link from the quotation) when the order is first originated.

Each delivery schedule is allocated to a work order which is then used for shop floor scheduling and production planning. For any one item, multiple delivery schedules from multiple customer order can be planned into one or more work order - providing the flexibility, and economy, of manufacturing (for example) one batch covering 3 months requirement made-up of 13 weekly deliver schedules.

Allocation of delivery quantities against delivery schedules generate delivery notes and sales invoices.

Sales invoice details can be exported to a file suitable for updating an external accounting system

Scheduling

All work orders (and underlying sub-assemblies or components) are expanded to their constituent operations and scheduled using manufacturing instruction based operations and times.

Operation details are then combined, by day, to provide the overviews of planned vs available capacity. Available capacities are specified through resource codes which represent the various machines or processes within the enterprise.

Each resource is specified with a daily overall capacity available and maximum capacity to be planned against any one job per day.

In addition a percentage is specified against each day of the week which reflects each days available capacity as a percentage of the normal working hours (e.g. Monday to Thursday may be 100% with Friday being 60% and Saturday being 20% - thus representing a typical early finish on Fridays and morning shift on Saturdays).

Time Recording

Each employee is provided a bar coded employee card and every work order has a bar coded route card.

These bar codes are read by the shop floor data capture terminals (that utilize a standard on-line P.C. together with a touch screen monitor and bar code scanner) to ensure information can be quickly and easily captured. No keyboard or mouse use is required.

Tooling

This module controls the status of all tools & gauges, when they were last calibrated and which are now due for calibration.

Probably the major cost benefit provided over manual and other forms of control is in reducing the number of items requiring calibration by tracking how shop floor usage. Time held within the tooling & gauging department does not contribute to service days between calibrations - this can considerably reduce the volume of items requiring calibration.

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