Rayterton ERP for Manufacturing

End to end plant lifecycle platform

Rayterton ERP for Manufacturing is an end to end plant lifecycle platform designed for manufacturers to plan and execute production with finite capacity discipline, control procurement and inventory with audit ready evidence, manage engineering change safely, and close finance with cost traceability from material to margin.

Implementation Philosophy and Experience

With Rayterton that specializes in customizing solutions to fit your needs 100%, you do not need to worry about disruption or change the system can follow your existing business processes and operations.

• Phased rollouts, go live on specific modules with your own pace
• Existing processes respected and emphasized
• Change requests included in maintenance; no fear of missing out important business needs during initial implementation phase

Sequence of Implementation

1. Setup Foundation and Master Data
2. Define BOM and Routings
3. Configure Planning Policies
4. Enable Procurement Controls
5. Establish Warehouse Execution
6. Release Production Orders
7. Run Finite Scheduling
8. Execute Quality and CAPA
9. Activate Traceability
10. Close Costing & Close Finance
11. Profitability Cockpit

Executive Manufacturing Command Center

Monitor everything in your manufacturing business from a centralized command center, complete with dashboards equipped with everything you need to monitor and make decisions. Give leadership a real time control view of service, capacity, quality, inventory, and margin exposure. Includes Executive KPI Cockpit (OTIF, OEE, yield, scrap, inventory turns, working capital, margin), exception tiles (late orders, material shortage, capacity overload, quality holds), and drilldown to planning, execution, quality, and finance. This module feeds prioritized exceptions into Order to Cash, MRP and Scheduling, Procurement, Production Execution, Quality, and Costing, and consolidates outcomes back into executive evidence packs.

End to End Order to Cash Control Tower

Visualize backlog risk by plant and week, protect customer service with exception based orchestration, and keep finance aligned with fulfillment reality. Includes Order timeline control tower, backlog heatmap by plant and week, ATP signals connected to MRP and finite schedule, shipment and invoicing readiness, and service recovery workflow for late or partial deliveries. This module pulls supply, capacity, and constraint signals from MRP and Finite Scheduling, triggers fulfillment through Warehouse Execution, and activates invoicing and margin trace into Costing and Profitability.

MRP Exception Monitor and Pegging

Detect shortages, safety stock breaches, and late supplies, then resolve them with pegging visibility that shows exactly which sales orders, production orders, and customers are impacted. Includes MRP exception inbox, pegging chain visibility, shortage resolution actions (expedite, substitute, reschedule, split), and governance controls for actions that impact cost or schedule. This module feeds prioritized shortages into Procurement and Production Dispatch, updates promise dates for Order to Cash, and outputs audit payloads and board packs for governance review.

Finite Scheduling Control Board

Schedule production with finite capacity, minimize changeovers, and protect critical windows with approval fences. Run what if simulation before committing changes, and keep the plant stable under demand volatility. Includes Finite capacity scheduling board, changeover aware sequencing, dispatch windows and frozen fences, simulation with deltas, and controlled approvals for schedule moves with service impact. This module pulls demand and constraints from MRP and Order to Cash, publishes executable sequences into Production Execution, and writes every schedule decision into audit evidence for performance and governance review.

Engineering BOM and Change Control

Control BOM versions, routings, and effectivity dates with workflow discipline so production, procurement, and costing always use the correct revision. Prevent uncontrolled substitutions and reduce scrap caused by unmanaged change. Includes Engineering BOM, routing versions, alternates and substitutions, effectivity windows, ECO workflow, impact analysis, and release control to production. This module feeds released BOM and routing versions into MRP, Procurement, and Production Orders, and updates standard cost structures that flow into Costing, Variance, and Profitability.

Procure to Pay Spend Control Tower

Convert MRP signals into purchase requests, compare RFQs with supplier performance context, enforce approvals with matrix governance, and complete 3 way match with evidence packs ready. Includes MRP driven PR creation, RFQ comparison, approval fence and matrix, PO release, 3 way match policy, supplier performance signals, and exception handling for shortages and expedite. This module pulls demand from MRP and dispatch needs from Production, issues PO commitments that protect service, and feeds goods receipt and invoice matching into Inventory, Costing, and Finance controls.

Warehouse Bin and Wave Execution

Execute warehouse operations with bin level control and wave discipline. Improve picking speed, reduce mispicks, and protect production kits and customer shipments with barcode workflows and real time task visibility. Includes Bin master and slotting, wave planning, pick pack ship, kitting for production, cycle count and variance control, and exception handling for shortages and damages. This module pulls demand from Order to Cash and Production Dispatch, confirms material readiness back to Production Execution, and posts inventory movements into Costing, Traceability, and Finance.

Production Order Control Tower

Run the shopfloor with one operational cockpit. Track dispatch readiness, material kitting, progress against plan, and constraint risks in one view. Resolve issues early with controlled actions that protect service and cost. Includes Production order control tower, dispatch window control, material readiness and shortage watchlist, progress against plan, labor and machine checkpoint signals, and exception driven actions. This module consumes the finite schedule and releases work to execution, sends consumption and completion signals into Costing, and triggers quality checks and traceability capture at each step.

Quality CAPA and Nonconformance Hub

Control quality with closed loop discipline. Capture NCRs, enforce containment, drive root cause and corrective actions, and verify effectiveness before closure. Keep quality decisions traceable and ready for audits. Includes NCR inbox, containment actions, CAPA workflow with approvals, defect analytics, supplier and process linkage, and effectiveness checks. This module blocks or releases inventory for Warehouse and Production, updates supplier performance for Procurement, and writes auditable quality evidence that links to Lot Genealogy and compliance reporting.

Lot Genealogy and Traceability Tree

Trace every lot from supplier to finished goods to customer shipment. Execute recalls with confidence by identifying scope in minutes, not days. Build compliance grade genealogy for regulated industries and export readiness. Includes Lot and batch genealogy tree, upstream and downstream trace, recall scope builder, quality holds and dispositions, and evidence export for auditors and customers. This module pulls lot events from Procurement, Warehouse, Production, and Quality, and feeds cost and margin attribution into Actual Costing and Profitability.

Actual Costing and Variance Analysis

Close the loop between operations and finance with real actual costing. Reconcile material, labor, overhead, and variances by order and by product. Turn variance from a monthly surprise into a controlled operational action list. Includes Actual cost rollup by work order, variance drivers (usage, rate, yield, overhead), reconciliation views, and governance ready postings aligned to finance close. This module consumes transactions from Production and Warehouse, validates standards from Engineering, and outputs financial postings and variance evidence into Finance and Profitability.

Profitability by Product and Customer

Move from cost reporting to profit decisions. Analyze profitability from period summary down to invoice line cost allocation and margin drivers. Keep "cost trace on" so leaders can defend margin actions with evidence, not assumptions. Includes Profitability cockpit, product and customer margin ranking, cost allocation trace to material and operations, mix and price waterfall, and action list for margin leakage. This module pulls actual cost evidence from Costing, revenue and terms from Order to Cash, and supplier and quality signals from Procurement and Quality to explain margin with operational drivers.

Glossary

ATP (Available to Promise)
A method to calculate product cost based on real, recorded expenses (materials, labor, and overhead), so the cost reflects what actually happened in production.

BOM (Bill of Materials)
A complete list of all parts, components, and materials needed to build a product. Similar to a recipe for making a product.

CAPA (Corrective and Preventive Action)
A quality process to fix problems (corrective) and prevent them from happening again (preventive).

ECO (Engineering Change Order)
An official request to change a product design, BOM, or production process, including version and revision control.

MRP (Material Requirements Planning)
A planning system that calculates what materials are needed and when, based on demand, BOM, and production schedules.

NCR (Nonconformance Report)
A report created when a product or process does not meet required specifications.

OEE (Overall Equipment Effectiveness)
A performance metric that combines machine availability, speed, and quality into one score.

O2C (Order to Cash)
The full business process from receiving a customer order to collecting payment.

OTIF (On Time In Full)
A customer service measure showing whether orders are delivered on time and in the correct quantity.