Production Management - Enterprise Resource Planning - ERP

Production Management

Managing production processes under full control, using resources efficiently and creating a traceable production infrastructure that complies with regulations are the cornerstones of a competitive production operation.

Konektom ERP's Production Management Module digitally manages all production stages from raw material input to finished product by supporting serial-based production, prescription production, process and discrete production models. Thanks to its GMP-compliant structure, it works fully integrated with quality control processes, providing traceability, process optimization and operational efficiency.

With the integration of SCADA, IoT and MES, real-time data flow is provided and production processes are monitored instantly. Machine and operator performance, production orders, quality controls and traceability mechanisms minimize the margin of error and increase the reliability of the processes.

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Production Management

The production management module is an integrated management solution that is GMP compliant and covers all stages from production planning to quality control processes, from traceability to reporting.

Production Planning

Prescription Management

Production Process Management

Quality Control Management

Traceability

Reporting

Production Planning & Order Management

Production planning, order-based production management and raw material allocation plans are created to manage the production process efficiently. Maximum efficiency is achieved in production processes by optimizing capacity, equipment and workforce usage. With MRP integration, raw material needs are determined, supply processes are planned and production disruptions are prevented with automatic stock controls.

Features

Master Production Schedule (MPS) & Capacity Planning
Material Requirements Planning (MRP) Integration
Order Based Production Planning
Manufacturing Resources Management (Equipment, Operator, Space Usage)
Raw Material Reservation & Automatic Stock Control
Order Approval and Production Orders Management
Transaction History & Automatic Notifications

Master Production Plan (MPS) & Capacity Planning
Capacity planning is done according to production demands and the available resources are used in the most efficient way. MPS helps prevent bottlenecks by optimizing production orders.

Material Requirement Planning (MRP) Integration
Automatic demands are created for raw materials to be used in production by working in integration with the MRP system. Thus, material deficiencies are detected in advance and supply chain processes are optimized.

Order-Based Production Planning
Production planning is done based on customer orders. Tracking the production process on an order basis reduces inventory costs and ensures more efficient use of resources.

Production Resource Management (Equipment, Operator, Area Usage)
Machines, workforce and production areas used in the production process are systematically managed. Efficiency in the production process is increased by planning operators and equipment.

Raw Material Reservation & Automatic Stock Control
Raw materials required for production are automatically reserved and made ready before the production process. Stock levels are constantly monitored and automatic warnings are generated when critical levels are reached.

Order Approval and Production Order Management
Orders are verified with approval mechanisms before they are put into production. Automatic production orders are created for approved orders to speed up the process.

Transaction History & Automatic Notifications
All production planning processes are recorded and a transaction history is created. With automatic notifications, teams are informed about production planning, order status and stock changes.

Prescription & Formulation Management

The ratios of active ingredients (API), excipients, solvents and other auxiliary substances used in pharmaceutical production are determined in accordance with GMP and FDA regulations. Recipe management and formulation controls are systematically carried out in order to maintain quality and ensure traceability of processes in production processes. Formulation changes are recorded and version tracking is ensured, and production recipes are integrated into processes to ensure consistency and quality in production.

Features

Master Batch Record (MBR) Management
Recipe & Formulation Identification and Version Tracking
Critical Process Parameters (CPP) Identification
Material & Quantity Calculation (BOM - Bill of Materials)
Manufacturing Standards & Process Approvals
Formulation Cost Analysis & Optimization
Transaction History & Automatic Notifications

Master Batch Record (MBR) Management
All recipe details, raw material ratios and production steps of the production process are defined in the MBR (Master Batch Record) system. Thus, production processes are standardized and full traceability is ensured.

Recipe & Formulation Definition and Version Tracking
Formulation information is recorded for each product and past changes can be tracked with version management. Changes made are recorded in the system to ensure that the correct recipes are used in production.

Critical Process Parameters (CPP) Identification
Critical process parameters such as temperature, pressure, humidity, which directly affect quality in production, are determined and defined in the system. The determined CPP values are monitored throughout the process and compliance checks are provided.

Material & Quantity Calculation (BOM - Bill of Materials)
The quantities of materials to be used in production are calculated via BOM (Bill of Materials). In this way, the correct amount of raw material is allocated for each production batch and material management is optimized.

Production Standards & Process Approvals
Production standards in accordance with GMP, FDA and other regulations are defined and in-process approval mechanisms are created. Thanks to process approvals, quality control processes are carried out in an integrated manner with production.

Formulation Cost Analysis & Optimization
Cost optimization is done by calculating production costs on a recipe basis. Efficiency is increased by evaluating alternative raw materials and production processes.

Transaction History & Automatic Notifications
All formulation changes and recipe processes are recorded in the system, making past transactions traceable. Relevant teams are informed of updates with automatic notifications.

Production Process & Process Monitoring

It provides a management system that increases continuity and quality in production by ensuring that production processes are monitored on a daily operational basis. While instant production monitoring is performed with automatic data recording, production performance is measured in detail thanks to OEE (Overall Equipment Effectiveness) analysis and efficiency reporting. With IoT and SCADA integration, data from production machines are processed instantly and operational disruptions are minimized.

Features

Granulation, Tableting, Coating, Encapsulation, Sterile Filling Process Management
Continuous & Batch Based Production Modes
Instant Data Collection with IoT & SCADA Integration
Energy Consumption and Machine Performance Monitoring
Production Order Management & Approval Processes
Error Management & Workflow Correction Mechanisms
Transaction History & Automatic Notifications

Granulation, Tableting, Coating, Encapsulation, Sterile Filling Process Management
Different production techniques are defined in the system and the most appropriate method is determined for each formulation. Production processes are automatically monitored to ensure quality and consistency.

Continuous & Batch-Based Production Modes
Continuous production and batch-based production models are supported, enabling production processes to be optimized according to need.

Instant Data Collection with IoT & SCADA Integration
Data from production equipment is processed instantly with SCADA and IoT systems. The performance of production machines is monitored and faults are detected in advance.

Energy Consumption and Machine Performance Monitoring
Energy consumption is measured on a machine basis and efficiency analyses are performed. Unnecessary energy expenditures are detected and cost optimization is achieved.

Production Order Management & Approval Processes
Production orders are recorded in the system and controlled with approval mechanisms. Production processes are monitored instantly and work orders are updated.

Error Management & Workflow Correction Mechanisms
Errors that may occur during production are automatically detected and workflow mechanisms are activated to correct them.

Transaction History & Automatic Notifications
The entire production process is recorded and past transactions are made traceable. With automatic notifications, relevant teams are informed about production processes.

Quality Control & Conformity Management

GMP requirements, quality tests and certification processes are systematically managed to ensure quality assurance in production processes and to fully comply with international regulations. While laboratory analyses are monitored digitally with LIMS integration, product reliability is increased thanks to stability tests and environmental compliance controls. Acceptance, rejection and quarantine processes are controlled, ensuring full traceability of production batches.

Features

Quality Control Sampling Plans
Batch Based Quality Tests & Laboratory Analyses (LIMS Integration)
Drug Stability Testing & Environmental Compliance Management
Tests Compliant with FDA & EMA Requirements
Acceptance / Rejection / Quarantine Management
Expiration Date & Shelf Life Tracking
Transaction History & Automatic Notifications

Quality Control Sampling Plans
Samples taken from specified points during the production process are included in quality control processes and tested. Sampling plans are automatically created and tracked.

Serial Based Quality Tests & Laboratory Analyses (LIMS Integration)
Quality control processes of the products are carried out on a serial basis and analysis results are managed in a digital environment with LIMS integration. Test data is stored in the system to ensure traceability.

Drug Stability Tests & Environmental Compliance Management
Tests performed to ensure the stability of products under different environmental conditions are recorded. Compliance analyses are performed by evaluating shelf life.

Tests to Comply with FDA & EMA Requirements
Whether the products comply with international quality requirements such as FDA, EMA and GMP is verified through quality tests. Test results are reported and integrated with regulatory processes.

Acceptance / Rejection / Quarantine Management
Production batches accepted, rejected and quarantined as a result of quality tests are tracked through the system. Reasons for rejection are analyzed and corrective actions are taken.

Expiration Date & Shelf Life Tracking
The shelf life and expiration dates of the products are tracked to ensure that necessary actions are taken at the end of the specified period.

Transaction History & Automatic Notifications
All quality control processes are recorded in the system and a transaction history is created. With automatic notifications, quality and production teams are informed about test results and compliance processes.

Serial and Lot Tracking & Traceability

A serial and lot-based tracking system is used to ensure full traceability of production processes. Unique identification numbers are assigned to each production batch and product group and are tracked throughout the process. Thanks to full integration with ERP and warehouse management systems, every stage from production to shipment is recorded in a digital environment. While instant traceability of products is ensured with RFID and barcode technologies, recall management and detailed tracking processes are activated when necessary.

Features

Serial & Lot Number Tracking
Real Time Traceability & Actual Quantity Control
Recall Management
Forward & Backward Traceability (End-to-End Tracking)
Full Integration with ERP & Warehouse Management
RFID & Barcode Integration
Transaction History & Automatic Notifications

Serial & Lot Number Tracking
Unique serial and lot numbers are assigned to each product and batch during the production phase. Thanks to these numbers, all production, stock, shipment and recall processes can be easily tracked.

Real-Time Traceability & Actual Quantity Control
Quantity changes in the production process are monitored instantly, deficiency or surplus situations are detected in advance and error-free processes are ensured.

Recall Management
In cases of quality problems or incompatibility, a rapid and controlled recall is carried out based on the relevant serial or lot number.

Forward & Reverse Traceability (End-to-End Tracking)
Security and quality control processes are strengthened by ensuring traceability of products throughout the supply, production, storage and shipment processes.

Full Integration with ERP & Warehouse Management
Serial and lot tracking is integrated with ERP and warehouse management modules to optimize stock management and logistics processes.

RFID & Barcode Integration
Using RFID and barcode technologies, products are automatically identified, and warehouse entry and exit operations are carried out quickly and without errors.

Transaction History & Automatic Notifications
All traceability processes are recorded in the system and a transaction history is created. Teams are instantly informed about automatic notifications.

Reporting & Integration

Detailed analysis of the production process, efficiency and cost analysis and full integration with ERP are carried out at this stage.

Features

Real Time Production Reports
Machine & Operator Performance Analysis
OEE (Overall Equipment Effectiveness) Reports
Production Waste and Waste Tracking
Cost & Efficiency Reports
LOGO ERP, SAP, MES, LIMS, WMS, SCADA Integration
Transaction History & Automatic Notifications

Real-Time Production Reports
All data related to production processes are processed instantly, providing managers with detailed analysis and performance evaluation opportunities.

Machine & Operator Performance Analyses
Efficiency analyses are performed by monitoring the performance of machines and operators used in production, and bottlenecks and inefficiencies are identified.

OEE (Overall Equipment Effectiveness) Reports
evaluate the efficiency of production processes and identify areas for improvement by measuring machine availability, performance and quality rates.

Production Waste and Waste Tracking:
Waste and waste occurring in production processes are analyzed to minimize losses and ensure efficient material use.

Cost & Efficiency Reporting
Cost analysis of production processes is performed to optimize production planning and improve resource utilization.

LOGO ERP, SAP, MES, LIMS, WMS, SCADA Integration
All production processes are integrated with systems such as ERP, MES, LIMS, WMS and SCADA, thus automating data flow and accelerating process management.

Transaction History & Automatic Notifications
All production, cost and performance data are recorded and made available for historical analysis. Managers and relevant teams are instantly informed with automatic notifications.