The DBA Demand Driven Planning System

Demand driven planning is sweeping the manufacturing world with dramatic reductions in lead times and inventory.  DBA brings the demand driven revolution to small manufactures with a complete planning MRP system that guides all of your activities and replaces private silos that cause extra work and overstaffing.

Demand Driven Guides

Video - The DBA Difference

Features

  • Eliminates “bullwhip effect” errors caused by demand projections and BOM explosions
  • Reacts to firm demand from sales orders
  • Establishes target ship dates for make to order items
  • Replenishes stock in efficient quantities at demand driven intervals
  • Material allocator releases jobs to production in the correct order of assembly
  • Identifies bottleneck work centers for deploying workers and machines
  • Schedules work centers in job priority order to optimize production flow
  • Provides late jobs feedback to sales for customer communications

Bill of Materials

The bill of materials (BOM) provides the work center and item specifications that drive demand driven MRP, shop control, and product costing.

Bill of Material Guide

Video - Bill of Materials

Features

  • Defines specs for virtually any type of manufactured item
  • Unlimited levels in product structures
  • Revision Control for your manufactured products
  • Rapid BOM creation with BOM copy, routing generator, speed entry
  • BOM component import for highly customized products and use with CAD programs
  • Drives MRP demand through all levels of production
  • Routings and Work Centers provide labor specifications and drive priority based activities throughout your organization
  • Special Subcontract Routings ensure that subcontract services are seamlessly integrated in your overall manufacturing workflow
  • Provides process details for job travelers
  • Augments job travelers with linked documents that flow through to Jobs

Bill of Materials

  • One-off BOMs for customized items
  • Batch type BOMs
  • Active, pending, archived revisions
  • Components and usage quantities with speed entry
  • % Overage for components that encounter scrap during production
  • Component line item notes and reference designators
  • Multiple outputs for byproducts, co-products, disassembly, remanufacturing
  • Indented view and tree view

Items

  • 30 character part number and 60 character description
  • User-defined item categories
  • Multiple suppliers and supplier part numbers
  • Manufacturers and mfg part numbers
  • See Purchasing section below for more details on Item Sources

Linked Documents

  • Link drawings, images, spec sheets, web links to BOM parent and component Item IDs
  • Option to automatically pull linked documents into the Job

BOM Tools

  • Component replace = helps easily swap a new component Item or revision in all BOMs at once
  • Process replace – helps update or replace common routing processes across multiple BOMs
  • Where used – lets you quickly see all places where a component or subassembly is used

Work Centers

  • Hourly rates for labor and manufacturing overhead costs
  • Ability to fine tune your rates using Setup, Labor, and Mfg OH Factors
  • Capacity settings
  • Optionally define standard processes for rapid routing generation
  • Machines

Routings

  • Routing sequences by Work Center with setup hours and cycle times
  • Ability to add detailed routing tasks and notes to improve documentation
  • Job Days Inquiry to provide feedback on production times for a typical run size
  • Routing Costs Inquiry to show breakout of Setup, Labor, Mfg OH and Subcon Costs

Subcontractors

  • Subcontractors are a special type of Work Center for outside processing
  • Supplier cross-reference for subcon PO generation
  • Optionally define standard processes for rapid routing generation

Subcon Routings

  • Contains the costing and scheduling info for processing outside services
  • PO Notes flow through to the Subcon POs and Traveler Notes to the Job
  • Refer to the Shop Control section below for the Job Subcontracting Workflow

Costing

  • Special screen to manage estimated costs for your purchased items
  • Calculated shop rates for labor and manufacturing overhead costs
  • Multi-level cost rollup of your manufactured items
  • Refer to the Product Costing section below for more details

Inventory Control

Inventory control maintains the accuracy of on-hand quantities, which is essential for Demand Driven MRP.

Inventory Control Guide

Video - Inventory Control

Features

  • Complete inventory management system
  • Real-time transactions for accurate on hand quantities
  • Lot and Serial tracking by item
  • Default Receipt Location by Item accommodates Inspection and QC procedures
  • Mass Stock Transfer to Primary Location after the item passes inspection
  • Major inventory transaction screens are optimized for manufacturing efficiency with material allocations and prefill of quantities
  • Cycle Codes with scheduled stock counts for designated groups of items
  • No need for period end adjustments

Items

  • Default receipt location and primary storage location
  • Allowable locations and location groups
  • Lot and serial control designation
  • Up to 6 User Defined Fields for documentation and reports
  • Linked documents that can be copied to Jobs and SOs

Lot/Serial Control

  • Expiration control for perishable items
  • Auto-numbering option for serial numbers
  • Lot/serial tracking by inventory transaction

Inventory Management

  • Cycle codes with scheduled stock counts
  • Stock transfer by location
  • Stock adjustments
  • Stock counts for physical inventories and stock takes

Locations

  • Unlimited locations
  • Transitory locations for inspection or transit
  • Location groups for allowable stock items

Customizable Data Views

  • Stock Item List
  • Stock On Hand
  • Inventory Transaction Detail
  • Inventory Transactions Lot/Serial

Features

  • Time to Shipment targets set line item requirements that drive demand for your organization
  • Late Supply screen provide communication between status of Jobs in the Shop and your line item requirement dates
  • Line Item Requirement Date drives priority and Expected Ship Date is used as the customer communication date
  • Picking Manager allocates supply based on priority to ensure that you optimize your throughput
  • Priority Picking is followed by Shipping and Invoicing
  • Extensive pricing flexibility with Base Prices, Break Prices, Price Levels, Discounts, and Contract Pricing
  • Complete Sales Tax entry and reporting
  • Multiple currency capabilities

Customers

  • Multiple shipping addresses
  • Foreign currency assignment
  • Up to 6 User Defined Fields for documentation and reporting
  • Linked documents that can flow through to Sales Order

Pricing and Discounts

  • Base prices with quantity price breaks
  • Next base price and mass update options
  • Price levels based on percentage of base price
  • Contract pricing by customer
  • Discount codes and discounts with quantity breaks

Taxation

  • Handles USA and VAT/GST style taxation
  • Invoice form includes Canada tax itemization
  • Reporting by Tax Codes and Tax Authorities

Customizable Forms

  • Custom form layouts for Quote, Acknowledgement, Packing List, and Invoice
  • Apply custom format by SO type or individual Customers

Customizable Data Views

  • Selling Prices
  • Quotes
  • Open Sales Orders
  • Sales Order Bookings
  • Pick/Ship Not Invoiced
  • Shipments
  • Sales Order Invoices

Order Entry

  • Planned Time to Shipment establishes line item required date
  • Line item requirement inquiry drop down provides transparency of your planned target settings
  • The expected ship date is the customer communication date and can be freely moved.
  • Foreign currency processing
  • Handles blanket orders with multiple required dates
  • Speed entry for improved data entry
  • SO Line Notes and Invoice Notes flow through to Acknowledgments and Invoices

Late Supply Screen

  • Provides automatic communication between shop floor and sales team
  • An SO line will appear when the Job finish date is greater than the SO line item requirement date
  • This screen can be used to update the Expected Ship Date for improved customer communications

Picking Manager

  • The Picking Manager prioritizes ready to ship orders
  • The screen allocates supply across all demand in the system and ensures that you remain on your priority targets companywide
  • Pick lists and dispatch lists
  • Single-click picking with pre-fill option for fully allocated SO lines

Shipping and Invoicing

  • Customizable packing list form layouts
  • Shipping charges entry
  • Customizable invoice form layouts

Custom Manufacturing

Products can be rapidly engineered to order with all the efficiency benefits of Demand Driven MRP.

Custom Manufacturing Guide

Video - Custom Manufacturing

Features

  • Rapid customization with demand driven job and purchase order generation
  • Customize existing products or engineer products from scratch
  • Ideally suited for remanufacturing and disassembly

Quotes

  • Generates one-off BOMs for customized items
  • One-off BOM can originate from BOM copy or from scratch
  • Customizable quote form layouts
  • Quote conversion to sales order with estimated ship date

One-Off BOMs

  • Freely modify BOM details without affecting originating BOM
  • Optionally import BOM components from CAD program to One Off Item
  • Cost rollup establishes estimated cost
  • Job Days Inquiry helps determine job days allocation

MRP and Jobs

  • Generates custom to order jobs directly from sales order lines
  • Custom Jobs are handled seamlessly within the Demand Driven MRP workflow
  • Multiple job outputs ideally suited for disassembly and remanufacturing

MRP (Material Requirements Planning)

Demand Driven MRP is a planning system driven by sales order requirement dates.

MRP Guide

Video - Demand Driven MRP

Features

  • Keeps you competitive with faster times to shipment
  • Works for any size or type of manufacturing business
  • Common sense item settings drive all manufacturing activities
  • Eliminates manual planning methods
  • Lean inventory planning minimizes shortages and over-stocking
  • Generates consistent and reliable sales order ship dates
  • Generates efficient jobs and purchase orders within a coordinated priority based system
  • Verifying supplier sources and pricing in MRP updates history and improves inventory costing
  • Converting only firm demand eliminates job quantity changes and cancellations
  • MRP will proceed through all levels of production and align subassemblies and components with the planned start of  your jobs
  • Job schedule is self-adjusting when jobs are released to live production

Item Settings

  • Planned time to shipment calculation for sell items based on underlying settings
  • Lead days auto-calculated from to order subassemblies and components
  • Manufactured lead days establish planned start dates for production
  • Job days allocations establish job finish dates
  • Optional job days calculation from work center and routing settings
  • Purchased item lead days allocations establish PO due dates
  • Dynamic reorder points trigger replenishment jobs and POs from actual firm demand
  • Planned supply days establish job and PO quantities
  • Item review notes handle special planning requirements

MRP Generation

  • Planned time to shipment targets establish sales order line item required dates
  • Custom to order jobs generated directly from sales order lines
  • Multi-level job and purchase order generation in response to total net demand
  • Consolidates interdependent demand into single jobs and purchase orders
  • Ability to change purchase order supplier, price, or manufacturer part number during PO conversion process

Job Release

  • Allocates available material to jobs in start date order
  • Job release to live production based on material availability
  • Reschedules job finish date relative to job release date
  • Job traveler printing option with each release batch

Purchasing

Demand Driven MRP generates purchase orders so materials are on hand for job planned start dates.

Purchasing Guide

Video - Purchasing

Purchasing in a Foreign Currency

Features

  • Supports multiple suppliers and manufacturers per Item
  • Automatic purchase order generation without need for manual origination
  • Verify and create new Supplier Sources in MRP keeps your purchasing source history up to date
  • Verify supplier pricing in MRP PO conversion screen improves costing accuracy
  • Mass update estimated costs based on default supplier purchase price
  • Purchase order tracking facilitates communication with suppliers
  • PO Receipt to an inspection or QC location and generate PO Receipt labels

Item Sources

  • Item line cards with supplier part number, description, price, and unit of measure
  • Track manufacturer and mfg part numbers
  • Able to purchase in different unit of measure than stocking UM
  • Purchase source info can be updated from New Item creation, Item Sources, and MRP PO Conversion screens
  • Data import of purchase sources for mass price entry/updates by Supplier
  • Mass update estimated costs by default purchase price from BOM > Estimated Purchase Costs screen

Suppliers

  • Foreign currency designation
  • Multiple physical addresses and contacts

Purchase Orders

  • Foreign currency processing
  • USA or VAT/GST style taxation
  • PO detail line notes defined against Items flow through to the PO and PO form
  • Customizable PO form layouts stored against PO Type or Supplier
  • Email POs to supplier

Customizable Data Views

  • Item Sources
  • PO Lines Summary
  • PO Receipts
  • PO Invoices

MRP PO Generation

  • Generate POs to meet your firm demand through all levels of productiion
  • Use MRP Settings Review Note to provide special instructions during PO conversion (ie check pricing from multiple vendors)
  • Update supplier sources and pricing when converting POs

PO Schedule

  • Late purchase order tracking with dependent jobs inquiry
  • Expected date entry updates schedule for late receipts

PO Receipts

  • Optional receipt to QC inspection location with stock transfer to storage location
  • Customizable item labels at time of PO Receipt
  • Single-click receiving with pre-fill option
  • Stock status inquiry indicates where items are needed

PO Invoices

  • Match supplier invoice prices with PO receipt prices
  • Posts price differences to variance account
  • Closes fully matched PO lines
  • Creates AP Voucher for Financial Transfer

Shop Control

Work centers are run in job priority order so all jobs meet their required dates and orders ship on time.

Shop Control Guide

Video - Shop Control

Video - Job Subcontracting

Features

  • Releasing jobs with material reschedules the job finish date (the expected supply date)
  • Work Center queues provide immediate feedback on bottlenecks and where to deploy resources
  • Automatic job prioritization eliminates the need for manual job expediting
  • Running work centers by job priority boosts productivity and throughput
  • Real-time updating lets you know the status of any job or work center
  • Issue material where and when needed from the Work Center Schedule screen
  • Report labor completions from the work center schedule when sequences are finished

Job Release

  • Allocates available material to jobs in start date order
  • Job release to live production based on material availability
  • Reschedules job finish date relative to job release date
  • Job traveler printing option with each release batch

Job Subcontracting

Customizable Data Views

  • Closed Job Cost Summary
  • Closed Job Performance
  • Work Center Performance
  • Worker Performance

Work Center Processing

  • The Work Center Schedule screen is the heart of your Shop Control processing
  • Job sequences are listed in priority order in work center queues
  • Job materials are issued to work centers on a just in time basis
  • Single-click issuing with pre-fill option
  • Labor is updated as sequences are completed
  • Work center queue days identify bottlenecks that need attention

Job Schedule

  • Tracks overall status of jobs
  • Late job tracking with dependent jobs and sales orders inquiry
  • For released Jobs you can manually update the Job Finish date to reflect a delay in the Job finish
  • When the Job finish date is later than the SO requirement date it will show up on the SO Late Supply screen, improving communications between the shop floor and the sales team

Product Costing

Labor and manufacturing overhead costs are absorbed through job labor transactions into item inventory values and cost of goods sold for complete and efficient costing.

Product Costing Guide

Video - Product Costing

Features

  • DBA conforms to the generally accepted accounting principle (GAAP) that labor and manufacturing overhead must be reflected in Work in Process (WIP), Inventory Value, and Cost of Goods Sold
  • Hourly rates for labor and manufacturing overhead calculated from actual costs and hours
  • Periodically adjust shop rates based on production history and financial accounting costs
  • Labor and manufacturing overhead costing occurs automatically with job labor transactions
  • Item costs incorporate material, labor, subcontract, and manufacturing overhead costs
  • Inventory and work in process (WIP) tracking without need for period end adjustments
  • WIP is self adjusting and is auto-reconciled with Job Close

Shop Rates

  • Hourly shop rate for labor calculated from payroll cost and reported job hours
  • Hourly shop rate for mfg overhead calculated from actual costs and job hours
  • Shop rates apply to work center hourly rates and can be factored for exceptions

Cost Rollup

  • Estimated purchase costs for purchased items can be mass updated based on default supplier price
  • Multi-level cost rollup calculates estimated cost for manufactured items
  • Estimated cost includes material, labor, subcontract, and mfg overhead costs

Work in Process (WIP) Costing

  • Estimated job cost calculated from job routing and component details
  • Item inventory costs are applied to job material issue transactions
  • Work center hourly labor and overhead rates are applied to job labor transactions
  • Subcontract PO costs are applied to subcontract service receipts
  • Finished item receipts can be costed at actual or estimated job cost

Inventory and Cost of Goods Sold (COGS)

  • Item inventory costs include material, labor, subcontract, manufacturing overhead costs
  • Item inventory costs flow through to cost of goods sold

Financial Transfer

You continue using your accounting system without disruption for receivables, payables, banking, payroll, and financial reporting.

Financial Transfer Guide

Video - Financial Transfer

Features

  • Implement manufacturing without any disruption to your financial processes
  • Transfers summarized financial data to any accounting system
  • Transfers can be made by spreadsheet import or manual entry
  • No need for version synchronization or database connections
  • Transfers include foreign currency values and exchange rates

Transfer Menu

  • Customer invoice totals are transferred for receivables processing
  • PO-related supplier invoice totals are transferred for payables processing
  • DBA accounts are cross-referenced with accounts in your general ledger
  • Account totals are transferred for financial reporting

DBA Tools

DBA has many tools and resources available to help you improve your organization without the need for custom programming or special consultants.

Join the Demand Driven Revolution today!