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Comparison between Manual & Automated Production Process
| Process |
Manual Production Process |
Automated Production Process |
Advantage/ Benefits |
| (1) | The customer places an order for 100 pcs of item A. The sales department informs the production department to produce the items (with relevant documentation) | The customer places an order for 100 pcs of item A. The Sales department enters Sales Order |
Sales Order is captured in the System for future
retrieval, backlog analysis and management inquiry |
| (2) | The production department raises a manual production order to produce the 100 pieces as per the customer's request | Sales Order is converted to Manufacturing Order |
Automatic conversion of Sales Order to Manufacturing Order
saves time and minimizes mistakes |
| (3) | The production department issues a manual raw material requirement list to the store | The production department prints a pick list from the system | Automatic generation of pick list saves time and speeds up the initial preparation process |
| (4) | The store needs to check the stock availability of the raw materials manually |
Pick list will indicate stock availability. Material Requirement Simulation will also indicate if there are any shortages |
No need to physically check the stock quantity or check the
manual records |
| (5) | The store informs the production department of any shortage and requests the purchasing department to order the raw materials | Production can immediately notify purchasing department to raise P/O via Pick List if there is a shortage |
No additional step or manual work needed to raise P/O |
| (6) | If the production is to be scheduled when the raw material arrives, nothing will be carried out at this stage. However, if for some reason the production must be carried out based on the material available, the production department will then alter the production quantity to a smaller quantity so that partial production can be carried out. The process for stage (3) to (6) could be repeated until a production quantity is matched with the stock availability of the raw materials. | The system automatically “allocates” the material from the stock based on the Pick List quantity. |
Automatic allocation of all available stock prevents stock
from being "re-used" in another production process. |
| (7) |
The store raises the material issue voucher to record the
items that were issued out and deduct each item from the
stock card. |
When the items are picked from the stock, the production department will update the pick list. |
Automatic deduction of raw material stock when pick list is updated |
| (8) |
When the production is completed, the accounts department
will work out the total cost of material issued and compute
the unit cost of each produced item before entering the
stock in the ledger. |
Accounts department can enter other additional or miscellaneous cost involved in the production of the finished item. This will form part of the standard cost of the item |
Additional cost is automatically spread across the finished
product |
| (9) | The store will update the stock card manually for goods received from production. | Production receipt will update the stock with the quantity produced |
Automatically updates the finished item production quantity |
| (10) |
When the purchased raw material arrives, the entire cycle
(3)-(9) will be repeated until the production is completed. |
Sales department can issue the D/O and Invoice and deliver the goods to the customer. |
Automatic handling of all production tasks saves time and
speeds up the production process for a faster turn around
time. Hence improving customer satisfaction. |
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