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Process Manufacturing Software


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Fishbowl Manufacturing logo
 
Fishbowl Inventory is widely used across multiple process manufacturing industries. The system includes lot tracking and traceability features designed to help process manufacturers comply with government regulations.
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Fishbowl Inventory is widely used across multiple process manufacturing industries. The system includes lot tracking and traceability features designed to help process manufacturers comply with government regulations.
 
NetSuite logo
 
NetSuite is a Cloud ERP system that small to medium-sized manufacturers can use to manage their operations. NetSuite offers accounting functionality for manufacturers with features for payroll, billing & invoicing and more.
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NetSuite is a Cloud ERP system that small to medium-sized manufacturers can use to manage their operations. NetSuite offers accounting functionality for manufacturers with features for payroll, billing & invoicing and more.
 
IQMS MES Software logo
 
EnterpriseIQ by IQMS can support the needs of small to mid-sized process manufacturers across several industries. The system includes shelf life management, multi-level bill of manufacture, lot & serial tracking and more.
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EnterpriseIQ by IQMS can support the needs of small to mid-sized process manufacturers across several industries. The system includes shelf life management, multi-level bill of manufacture, lot & serial tracking and more.
 
SYSPRO logo
 
SYSPRO has been involved in the manufacturing software market for more than three decades. SYSPRO buyers benefit from an expansive network of over 1500 partners across the world that can help manufacturers customize their system.
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SYSPRO has been involved in the manufacturing software market for more than three decades. SYSPRO buyers benefit from an expansive network of over 1500 partners across the world that can help manufacturers customize their system.
 
Datacor Chempax logo
 
Chempax by Datacor is an integrated enterprise resource planning (ERP) and customer relationship management (CRM) application designed specifically for chemical process manufacturers and distributors. The solution can be scaled to... Read More
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Chempax by Datacor is an integrated enterprise resource planning (ERP) and customer relationship management (CRM) application designed specifically for chemical process manufacturers and distributors. The solution can be scaled to... Read More

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SAP Business One logo
 
Process manufacturing companies can find deep support of their business from SAP Business One, a prominent ERP solution. The software can manage yield variances, enable lot & recipe management, and foster expiration tracking.
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Process manufacturing companies can find deep support of their business from SAP Business One, a prominent ERP solution. The software can manage yield variances, enable lot & recipe management, and foster expiration tracking.
 
Kenandy Cloud ERP logo
 
Kenandy is a comprehensive cloud-based ERP solution created for companies that design, manufacture, or distribute products. It helps businesses manage core processes including order-to-cash, planning and production, procurement, TPM,... Read More
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Kenandy is a comprehensive cloud-based ERP solution created for companies that design, manufacture, or distribute products. It helps businesses manage core processes including order-to-cash, planning and production, procurement, TPM,... Read More
 
Exact Macola logo
 
Exact Macola is designed for mid-market manufacturers in the process industries such as food & beverage, plastics and more. Exact Macola is sold by the module, which means that buyers can buy only the functionality they need.
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Exact Macola is designed for mid-market manufacturers in the process industries such as food & beverage, plastics and more. Exact Macola is sold by the module, which means that buyers can buy only the functionality they need.
 
Mar-Kov CMS logo
 
Mar-Kov CMS (Chemical Management System) was developed to meet the unique needs of process, batch, and formulation based manufacturers. By automating daily routine processes, companies are able to streamline their operations while... Read More
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Mar-Kov CMS (Chemical Management System) was developed to meet the unique needs of process, batch, and formulation based manufacturers. By automating daily routine processes, companies are able to streamline their operations while... Read More
 
Rootstock logo
 
Rootstock Software is a cloud-based ERP solution designed for manufacturers and distributors of all sizes and across industry verticals. The software controls different aspects of the business - from sales and purchase order management,... Read More
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Rootstock Software is a cloud-based ERP solution designed for manufacturers and distributors of all sizes and across industry verticals. The software controls different aspects of the business - from sales and purchase order management,... Read More

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S2K Manufacturing Management Software logo
 
S2K for Manufacturing is an ERP suite for mid-sized process manufacturers. The IBM iSeries-based system is often deployed as an integrated suite of applications that includes point of sale, accounting and warehouse management.
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S2K for Manufacturing is an ERP suite for mid-sized process manufacturers. The IBM iSeries-based system is often deployed as an integrated suite of applications that includes point of sale, accounting and warehouse management.
 
Exact MAX Manufacturing logo
 
Exact MAX Manufacturing is a suite of applications focused on providing small and midsized businesses with intuitive control over their processes, from product and engineering revisions to regulatory compliance.
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Exact MAX Manufacturing is a suite of applications focused on providing small and midsized businesses with intuitive control over their processes, from product and engineering revisions to regulatory compliance.
 
Cetec ERP logo
 
Cetec ERP offers a suite of modern ERP, MRP, and QMS software solutions. Applications include ERP, Job Costing, Manufacturing Execution, Production Scheduling, ISO 9001 Management, Electronic Routers/Work Instructions, Inspection Reporting,... Read More
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Cetec ERP offers a suite of modern ERP, MRP, and QMS software solutions. Applications include ERP, Job Costing, Manufacturing Execution, Production Scheduling, ISO 9001 Management, Electronic Routers/Work Instructions, Inspection Reporting,... Read More
 
BatchMaster ERP logo
 
As the name suggests, BatchMaster ERP is designed purely for the batch manufacturing industries. BatchMaster targets mid-market process manufacturers in industries such as chemicals, food & beverage and pharmaceuticals.
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As the name suggests, BatchMaster ERP is designed purely for the batch manufacturing industries. BatchMaster targets mid-market process manufacturers in industries such as chemicals, food & beverage and pharmaceuticals.
 
Oracle SCM Cloud logo
 
Oracle SCM Cloud offers a full suite of applications for companies to manage their supply chain, distribution, manufacturing, inventory management, and fleet.  Using product development, users can create a detailed bill of material... Read More
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Oracle SCM Cloud offers a full suite of applications for companies to manage their supply chain, distribution, manufacturing, inventory management, and fleet.  Using product development, users can create a detailed bill of material... Read More

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abas ERP logo
 
Abas ERP is a solution geared towards small to midsized manufacturers and distributors. Abas has three main application offerings on the market today: Abas ERP, Abas Distribution and Abas eB, a line of e-business solutions that... Read More
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Abas ERP is a solution geared towards small to midsized manufacturers and distributors. Abas has three main application offerings on the market today: Abas ERP, Abas Distribution and Abas eB, a line of e-business solutions that... Read More
 
bcFood logo
 
bcFood by Beck Consulting is a complete Enterprise Resource Planning system designed specifically to meet the unique needs of food manufacturers, processors, and distributors both small and large. bcFood is built on Microsoft Dynamics... Read More
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bcFood by Beck Consulting is a complete Enterprise Resource Planning system designed specifically to meet the unique needs of food manufacturers, processors, and distributors both small and large. bcFood is built on Microsoft Dynamics... Read More
 
HYDRA logo
 
HYDRA by MPDV USA is a fully integrated Manufacturing Execution System (MES) that helps organizations collect and analyze critical data related to production, HR, and supplier management. With HYDRA, manufacturers can gather real-time... Read More
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HYDRA by MPDV USA is a fully integrated Manufacturing Execution System (MES) that helps organizations collect and analyze critical data related to production, HR, and supplier management. With HYDRA, manufacturers can gather real-time... Read More
 
Infor Process Manufacturing Essentials logo
 
Infor Process Manufacturing Essentials is built to handle the needs of midmarket and large manufacturing firms from a variety of segments. The system supports firms in chemicals, consumer products, plastics & rubber and more.
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Infor Process Manufacturing Essentials is built to handle the needs of midmarket and large manufacturing firms from a variety of segments. The system supports firms in chemicals, consumer products, plastics & rubber and more.
 
Geneva Business Management Systems (GBMS) logo
 
Geneva Business Management Systems was founded in 1994 and offers support for process manufacturing segments like food & beverage. The system is offered as either an on-premise system or as a browser-based solution.
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Geneva Business Management Systems was founded in 1994 and offers support for process manufacturing segments like food & beverage. The system is offered as either an on-premise system or as a browser-based solution.
 

Buyer's Guide

by Daniel Harris,
Market Research Associate
Last Updated: April 28, 2017


Gartner defines process manufacturing as, “manufacturing that adds value by performing chemical reactions or physical actions to transform materials, or by extracting, mixing, separating or forming materials in batch or continuous production modes.”

Process manufacturers generally deal with products that pour, such as liquids or powders, and are produced in bulk quantities. It includes industries, such as chemicals, pharmaceuticals, food and beverages and gasoline.

A process manufacturing system must balance four constraints. First, the batch size is constrained by the amount of product on order and stock quantities to be kept on hand. This is particularly key when using materials or creating a product with a limited shelf life. The second constraint is ingredients, as the most limited ingredient determines how much product can be made. Then, there’s packaging inventory, and one of the challenges of process manufacturing is that you need to store the final product in something. The fourth constraint is capacity—or the ability to make a product within the production facility itself.

The critical function of a process manufacturing system is inventory control. One important feature of the inventory system is the ability to manage different units of measurement, for example, determining how many liters of an item are available when it is received in 55 gallon drums. Related to inventory is recipe management, that is, how to alter the formula to make a certain amount or to use available inventory.

On the other hand, a process manufacturing system can be part of an enterprise resource planning (ERP) system, or be part of a best-of-breed set of solutions. It is also possible to integrate with a manufacturing execution system (MES). Accounts payable, accounts receivable, payroll and general ledger are the standard features of these systems. While most installations use on-premises equipment, cloud-based options are also available. Software as a service (SaaS) viability is primarily dictated by the value of installed technology base, but projected maintenance costs of both hardware and software is an important factor as well.

What Is Process Manufacturing Software?

Henry Ford once said, “If you always do what you always did, you’ll always get what you’ve always got.” Manufacturers must heed these words and always strive to make business processes more efficient. Some of the major concerns they face include:

  • Increase in production cost
  • Highly competitive local and global environment
  • Short product life cycle
  • Reduction of profit margins
  • Considerable improvement in quality assurance metrics

Process manufacturing software is designed specifically to manage these complexities. For manufacturers, fulfilling regulatory compliance by tracing ingredients and industrial waste is pivotal. Therefore, across the globe, executives are considering process manufacturing platforms to monitor business processes from end-to-end, that is, from production to delivery.

It is important to note that manufacturing executives can extend process manufacturing capabilities with their existing ERP or MES solutions as an additional module or integration. Furthermore, numerous vendors in the market offer specialized solutions for process manufacturing businesses. Executives should involve all the stakeholders to list out the requisite capabilities in a solution. In addition, buyers should evaluate the suitability and capability of the solution vis-à-vis their requirements before adapting the solution.

Process manufacturing professionals should focus on resolving the following challenges via a process manufacturing platform:

  1. Mitigate product risks and recalls
  2. Increase a product’s time to market
  3. Track and monitor business performance
  4. Accurately forecast product demand and supply chain issues
  5. Achieve regulatory compliance

There are many objectives that can be achieved with the help of a process manufacturing application. Manufacturing organizations with mobile employees and remote workstations should ideally look for solutions that also offer mobile applications.

Common Features of Process Manufacturers Software

In evaluating software, process manufacturers should consider the following functions to meet their unique requirements:

Delivery-driven production Delivery-driven production matches the batch size to the amount on order plus the quantity to be kept on hand. The system should also verify that all other constraints are met.
Ingredient-driven production Ingredient-driven production matches the batch size to the available quantities of the ingredients on hand. The system should also verify that all other constraints are met.
Packaging-driven production Packaging-driven production matches the batch size to the finished amount that can be packaged with materials on hand. The system should also verify that all other constraints are met.
Capacity-driven production Capacity-driven production matches the batch size to the maximum capacity that the floor can produce. The system should also verify that all other constraints are met.
Critical path production If the process has stages with delays in between, such as a fermenting stage, then the system can match orders of ingredients to the time when they are required. This can save money in initial production costs by delaying purchases until required but runs the risk of loosing a batch if a required ingredient is not available in time.
Expiration tracking Both ingredients and products can have limited shelf lives. The system needs to track expired and close-to-end-of-life inventory.
Recipe management The system should include recipe management, including ingredient substitution. In some cases, ingredients are encoded to keep recipes secret.
Lot management Each lot must be identified and tracked. The ingredients of each batch must be tied to their individual batch number as well.
Yield variances The system should track actual yield versus expected yield for each batch. The system should report excessive variance based on user-defined thresholds and indicate if variances are so large that regulating agencies should be notified.
Current Good Manufacturing Practice (cGMP) compliance cGMP compliance is required for many regulatory agencies at the state and federal levels as well as for insurance purposes. The system should produce required compliance reports.
Units of measure management The system should convert units of measurement as required for inventory management, order processing, receiving and batch production.
Available to promise, capable to promise Available to promise (ATP) and capable to promise (CTP) are measures of manufacturing capacity. The system should calculate the ATP and CTP for any stock item, accounting for ingredients on hand and any work in process.
EPA and OSHA compliance Manufacturers that make, use or have byproducts that are highly hazardous chemicals (HHCs) must comply with the EPA’s Risk Management Program (RMP) and OSHA’s Process Safety Management (PSM) regulations. The system should produce required compliance reports.

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Manufacturing Software Feature Checklist

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Ten Steps to Selecting the Right Manufacturing Software

 

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