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S2K Enterprise
S2K Enterprise
VAI is an independent software developer and the author of S2K Enterprise, an award winning cloud-based ERP solution utilized by customers operating across the distribution, manufacturing, specialty retail, and service sectors, wi...Read more about S2K Enterprise
IFS Cloud
IFS Cloud
IFS Cloud is a composable enterprise software application that orchestrates customers, people, and assets to reduce complexity, cost and risk as you plan, manage and optimize critical asset availability, strive for operational exc...Read more about IFS Cloud
Infor LN
Infor LN
Infor LN is a powerful ERP solution for managing end to end processes with greater efficiency and data driven insights. It is available on premises or in the cloud and is core to industry-specific solutions: CloudSuite Aerospace &...Read more about Infor LN
BatchMaster ERP
BatchMaster ERP
BatchMaster Software offers process manufacturing software solutions for the food, chemical, nutraceutical and pharmaceutical industries. Users can run the manufacturing application with QuickBooks, Sage 100&300, Microsoft Dynamic...Read more about BatchMaster ERP
SCP 4.0
SCP 4.0
Jada vendor management inventory and demand planning system is suitable for businesses looking to manage inventory holding costs and track service levels. SCP is offered as a best of breed application that is ideal for both midsiz...Read more about SCP 4.0
Manufacturing & SFC
Manufacturing & SFC
Transform your extensive manufacturing processes into easily accessible, efficient procedures. Geneva Systems offers MRP & Manufacturing Execution software. Our MRP & Manufacturing Execution module is a robust and comprehensive ...Read more about Manufacturing & SFC
NetSuite
NetSuite
With an integrated system that includes ERP, financials, commerce, inventory management, HR, PSA, supply chain management, CRM and more – NetSuite enables fast-growing businesses across all industries to work more effectively by a...Read more about NetSuite
PRIMS
PRIMS
PRIMS or "Product Recipe Ingredient Management System" is recipe management software for programmable logic controller-based ingredient batching systems. It offers recipe management, batch management, inventory control, lot tracki...Read more about PRIMS
ERP123
ERP123
ERP123 offers small and midsize manufacturers and distributors an ERP solution that automates and integrates business operations. This software allows the user to the organize their MRP, inventory management, picking and shipping,...Read more about ERP123
PBS Accounting
PBS Accounting
PBS Accounting is robust professional level accounting software that fits a wide range of businesses and grows with your company. The CashPoint version acts as back end accounting for NCR Counterpoint. Flexible, up to the minute r...Read more about PBS Accounting
SYSPRO
SYSPRO
About SYSPRO SYSPRO is an enterprise resource planning (ERP) solution that is industry-built and provides last-mile capabilities for manufacturing and distribution businesses. SYSPRO provides the solutions, processes, and tools to...Read more about SYSPRO
JD Edwards EnterpriseOne
JD Edwards EnterpriseOne
Oracle JD Edwards EnterpriseOne is an enterprise resource planning software with primary features such as real estate management, human capital management, environmental health and safety and commodity trading. What is JD...Read more about JD Edwards EnterpriseOne
Aptean Process Manufacturing ERP ProcessPro Edition
Aptean Process Manufacturing ERP ProcessPro Edition
Aptean Process Manufacturing ERP ProcessPro Edition is a complete Enterprise Resource Planning (ERP) solution for small to mid-sized batch process manufacturers to manage their business operations through manufacturing, sales, inv...Read more about Aptean Process Manufacturing ERP ProcessPro Edition
Fishbowl
Fishbowl
Fishbowl is the #1 manufacturing and warehouse inventory management software! Its powerful inventory control system gives your small or midsize business the exact tools needed to transform your inventory management and scale your ...Read more about Fishbowl
MISys Manufacturing
MISys Manufacturing
MISys Manufacturing is a cloud-based and on-premise manufacturing solution designed for small and midsized companies. It caters to electronics, food and beverage, aerospace, defense, chemicals, health and beauty, medical devices, ...Read more about MISys Manufacturing
DELMIAworks
DELMIAworks
DELMIAworks (formerly IQMS) ERP is developed specifically for SMB and large discrete and batch process manufacturers in the aerospace, medical device, automotive, food and beverage, consumer products, plastics, packaging, and elec...Read more about DELMIAworks
Visibility ERP
Visibility ERP
Visibility ERP is a fully integrated and modern ERP solution designed to meet the unique needs of manufacturers of complex products (including To-Order, ETO, CTO, MTO, Project Based, Discrete and Hybrid). It provides manufacturers...Read more about Visibility ERP
Enterprise 21 ERP
Enterprise 21 ERP
Enterprise 21 ERP from TGI is a cloud-based enterprise resource planning (ERP) solution that provides small and midsize businesses across various industry verticals tools and functionalities to manage day-to-day operations and rou...Read more about Enterprise 21 ERP
Plex Smart Manufacturing Platform
Plex Smart Manufacturing Platform
Plex gives manufacturers the ability to connect, automate, track and analyze every aspect of their business -- from the plant floor to the top floor -- to drive business transformation. Built in the cloud, the Plex Smart Manufactu...Read more about Plex Smart Manufacturing Platform
R4 Enterprise
R4 Enterprise
Royal 4 Enterprise is an integrated enterprise resource planning (ERP) solution with built-in modules for distribution, manufacturing, planning, inventory management, reporting and company financials. It serves midsize to large en...Read more about R4 Enterprise
Buyers Guide
Last Updated: March 16, 2023Gartner 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.
In this buyers guide, we'll cover:
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:
Mitigate product risks and recalls
Increase a product’s time to market
Track and monitor business performance
Accurately forecast product demand and supply chain issues
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. |