Process Manufacturing Software

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.

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Showing 1 - 20 of 121 products
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Showing 1 - 20 of 121 products

Fishbowl

Fishbowl is a hybrid manufacturing and warehouse management solution designed for small and midsize companies. Key features include inventory control, material requirements planning (MRP), job shop floor control, work order manage...Read more

4.17 (731 reviews)

99 recommendations

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

4.10 (818 reviews)

80 recommendations

Striven

Striven is a cloud-based enterprise resource planning (ERP) solution suitable for many industries and organizations of all sizes. It offers features for accounting, inventory management, human resources, customer relationship mana...Read more

4.80 (49 reviews)

52 recommendations

24SevenOffice

24SevenOffice is a cloud-based Accounting and ERP system for small and mid-sized businesses. 24SevenOffice eliminates repetitive processes and greatly reduces the need to manually enter information. The system will also streamline...Read more

4.41 (29 reviews)

35 recommendations

PriceDemo

Prodsmart

Prodsmart is the SMB manufacturer’s gateway to digitization. It’s a complete, modular solution that gets any production environment ready for the future of manufacturing. Prodsmart empowers SMBs with data. By gathering insight o...Read more

4.71 (73 reviews)

33 recommendations

Katana Manufacturing ERP

Katana Manufacturing ERP is a manufacturing ERP that gives you a live look at all the moving parts of your business — sales, inventory, and beyond. Combining a visual interface and smart real-time master planner, Katana makes mana...Read more

4.77 (137 reviews)

25 recommendations

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DELMIAworks

EnterpriseIQ by IQMS is a comprehensive ERP solution designed to meet the needs of discrete and repetitive manufacturers. Because it's fully scalable, it can grow with any company. ...Read more

4.06 (286 reviews)

22 recommendations

Intellect

Intellect provides a flexible enterprise Quality Management Software (eQMS) solution and platform designed to meet any FDA and ISO compliance requirements, as well as digital transformation goals. Built on the Intellect Compliance...Read more

4.53 (55 reviews)

12 recommendations

Mar-Kov Chemical Management System

Mar-Kov CMS (Chemical Management System) is a cloud-based process manufacturing solution for process, batch, and formulation based manufacturers. The solution can also be installed on-premise to automate daily routine processes of...Read more

5.00 (1 reviews)

10 recommendations

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ERPAG

ERPAG is a cloud-based enterprise resource planning (ERP) solution. It is suitable for small and midsize businesses in various industries, including automobile, retail, education, information technology and more. Primary features ...Read more

4.56 (266 reviews)

8 recommendations

PriceDemo

Software pricing tips

Read our Process Manufacturing Software Buyers Guide

Subscription models

  • Per employee/per month: This model allows you to pay a monthly fee for each of your employees.
  • Per user/per month: Users pay a monthly fee for users—normally administrative users—rather than all employees.

Perpetual license

  • This involves paying an upfront sum for the license to own the software and use it indefinitely.
  • This is the more traditional model and is most common with on-premise applications and with larger businesses.

Rated best value for money

Fiddle

Fiddle is a cloud-based solution that enables businesses to streamline the entire inventory lifecycle, from tracking stock levels across locations to creating shipping orders. It allows users to plan or allocate tasks among team m...Read more

5.00 (1 reviews)

8 recommendations

PriceDemo

Sage X3

Sage X3 is a powerful ERP software solution designed for midsized national and global manufacturers, distributors, and after-sales providers and can establish a foundation for your digital transformation. Sage X3 comes with indust...Read more

4.29 (50 reviews)

6 recommendations

PriceDemo

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

4.22 (96 reviews)

5 recommendations

PriceDemo

Aquilon ERP

Aquilon is an ERP program that supports SCM, manufacturing, distribution, and accounting functions. The program is suited for SMBs and can be used in the cloud or on local servers....Read more

4.61 (36 reviews)

5 recommendations

SafetyChain

SafetyChain is a Plant Management Platform that improves yield, maximizes productivity, and ensures compliance for process manufacturers. Trusted by over 1,500 facilities, SafetyChain is the only enterprise solution uniting produc...Read more

4.56 (25 reviews)

5 recommendations

Vicinity

Vicinity Software is a cloud-based or on-premise solution designed for process manufacturers with a specific focus on food & beverage (VicinityFood), chemical (VicinityChem) and breweries (VicinityBrew). Features include MRP, cent...Read more

4.33 (3 reviews)

5 recommendations

Connected

Connected is a hybrid integrated accounting and enterprise resource planning (ERP) that caters to small and midsize businesses across various industry verticals and helps them to integrate their data and processes across departmen...Read more

5.00 (3 reviews)

4 recommendations

iNECTA Food

iNECTA is a provider of ERP software partnered and powered by Microsoft Dynamics 365. Specializing in multiple industries, iNECTA’s solutions are catered to fit the needs of small to medium sized businesses specifically. iNECTA Fo...Read more

No reviews yet

4 recommendations

PriceDemo

SyteLine

SyteLine is an enterprise resource planning software created specifically for engineer-to-order, make-to-order, make-to-stock, and mixed-mode manufacturers. Customers in both discrete and process manufacturing can benefit from thi...Read more

3.89 (64 reviews)

3 recommendations

Aptean Food & Beverage ERP JustFood Edition

JustFoodERP is a fully integrated Enterprise Resource Planning solution developed and customized for food and beverage manufacturers and distributors. JustFoodERP helps lower costs while improving food safety and compliance....Read more

4.50 (14 reviews)

3 recommendations

Buyers Guide

Last Updated: May 24, 2022

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.

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:

  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.