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What is ERC?

Enterprise Resource Control (ERC) is a revolutionary system specifically designed for manufacturing and warehousing to take control of inventory accuracy and all aspects of operations.  ERC combines RFID, real-time asset tracking technology with proprietary cutting-edge software, creating an all-in-one solution to transact, monitor and drive activities and business decisions in real time.

Why ERC?

ERC user-friendly all-in-one solution, integrated with ERP or stand alone, eliminates the need to purchases any additional modules or systems such as warehouse management, work order production, scheduling or quality control.

Our expert project manager will drive a quick non-disruptive implementation including hardware/software installation, user training and 24/7 technical support. ERC also comes with short training videos in every module for continuous user assistance.

ERC provides smart tools and business analytics to maximize profits.

Seeing is believing, witness ERC in action by scheduling an in-person system demonstration with one of our gracious clients located in Los Angeles, California.

System Modules and Highlights

WAREHOUSE

  • Receiving Module
  • Return Module
  • Cycle Count Module
  • SO Staging Module (FIFO Driven)
  • Shipping Module
  • Auto Item Location Tracking
  • More……

PRODUCTION

  • Work Order Module
  • WO Staging Module (FIFO Driven)
  • Lot Cost Calculated
  • Variance Reasons
  • Reports And Analysis
  • More……

SCHEDULING

  • Electronic Scheduling
  • Electronic WO’s
  • Manage Direct Labor
  • Real Time Production
  • Reports & Analysis
  • More……

QUALITY CONTROL

  • Assign Hold Reason Codes
  • Disposal Approval
  • Reports & Analysis
  • More…

REAL-TIME ALERTS

  • FIFO Violations
  • Unauthorized Activities
  • High Material Usage Variances
  • Short Shipping Customer
  • More……

EXECUTIVE DASHBOARD

  • Margin Analysis By Lot
  • Productivity Variance
  • Line Utilization
  • Material Usage Variance
  • Inventory Analytics
  • Shop Floor Monitoring
  • More…

System Details

Senitron’s ERC solution stands out by combining RFID with proprietary Software resulting in an entire manufacturing facility using ERC’s unified platform to transact every action. From the personnel on the warehouse floor receiving purchase orders in ERC and applying RFID labels, to the production managers scheduling productions in ERC scheduler, the sales team checking RFID real-time inventory, order fulfilment crew using ERC to locate, pick and ship inventory, all the way to upper management being able to observe, analyze and make informative business decisions using ERC’s management dashboard.

Manufacturing Modules

Work Order Scheduling

Production schedulers can quickly pull up production calendar to view line utilization and activities and schedule new productions with a click of a button.

  • Production Status
  • Actual Qty Produced vs Goal
  • Direct Labor
  • Usage Variance %
  • Notes

Work-Order Staging

Pickers can see the upcoming productions with items and quantities needed to start staging. All available items are sorted per FIFO and shown on the map. Management will receive an auto alert email if any FIFO violations occurred. Once staging is complete, the WO status in production calendar changes to “Staged and Ready”.

Work Order Labeling

  • As finished goods are produced, employee inputs the details of the content of each pallet and prints & applies RFID label to each pallet. This process automatically progresses the production until it is completed.
  • Management and crew have a “Live” view of what has been produced and what is pending.

Work Order Consumption / Closure

Once production is completed, employee scans consumed RFID labels against WO. Material usage variance outside allowable percentages requires explanation. Management will receive an auto alert email if any consumed items were not a part of BOM or allowable substitutions.

RFID INVENTORY

Inventory On-Hand

Employees can easily browse through total inventory and filter as needed.Each RFID inventory tag has a story. Anyone can add a note or see how and when it was created, movement history to current location, when and how it was consumed or sold, etc.

Selected item detail will show current total quantity available on-hand after deducting quality hold, expired and allocated quantities, as well as expected production, consumption, and purchase order quantities, and RFID last-seen location/date/time. “Show Subs” button will display all available substitutions.

Warehousing Modules

Receiving

Purchase Order & Returns

Receive Purchase Orders

  • Receiving personnel can quickly and accurately receive goods against purchase orders. System prompts to enter relevant information including # of pallets and # of cases per pallet.  After math validation is confirmed, system allows to print labels.

  • Once RFID labels are printed and read by overhead RFID sensors, they are ready to be attached completing the receiving process.  ERC’s proprietary receiving module eliminates 99% of human errors.

Receive Returns
Quickly process returns against sales orders. ERC auto loads the previously sold items and allows user to input the total amount returned.  The returned items are RFID labeled and put back into inventory with quality hold status. Quality department is automatically notified.

Order Fulfillment

ERC has two options for order fulfillment: Sales Order Picking  and Quick-Ship module.

Sale Order Picking

  • The general sales order fulfillment module follows a pipeline approach where orders to be fulfilled are assigned or self-assigned to be picked. Assign > Packing > Inspect & Approve > Ship
  • Pickers fulfilling orders are guided by FIFO and pointed by RFID to last-seen location. Management will receive an auto alert email if any FIFO violations occurred.
  • Once picked and staged, supervisor can inspect and approve shipping. ERC generates customized BOL, and once the order is shipped, supervisor approves it for billing.
  • Displays can be mounted around the facility to show the order fulfillment teams progress and activities in real-time.  Stats are available to show if personnel is picking FIFO, speed of SKU’s per minute, and more.  

RFID Quick Ship

  • The quick ship module is ideal for quickly loading up a truck with 50+ pallets, RFID reads the RFID labels on each pallet add to the screen, and with a click of a button it marks the items are sold and prints out an BOL on the fly, and Optionally also emails the BOL to your team and the client.
  • RFID of the pallets can be read automatically as they are loaded into the truck, or the RFID papers can be read quickly under a Wall mounted RFID reader.

Quality Control & Disposal

Quality Control

  • ERC quality hold module allows QA to easily place product on hold and create Quality Hold ID number. Quality hold tag is printed and applied to each pallet.
  • If product on quality hold is used by personnel in warehouse or production, management will receive an auto alert email notifying of QA hold violation.
  • When quality hold issue is resolved, the inventory is released, otherwise, it is marked for disposal.

Disposal

  • ERC disposal module allows QA create Inventory Destruction ID number and request approval. Depending on the dollar value threshold, appropriate manager will be notified for approval or rejection.

Advanced Features

Item Master | Catalog Management | UOM Support

  • Organizations can quickly add new items the item master through the catalog management screen.
  • ERC support conversions based on Units of Measure, so you can quickly define conversion between pallets to cases, to each’s, or Lbs to KG and more. 

Substitutions

  • Organizations can define Production BOM acceptable substitution items, and allows inventory search based on the primary item and substitution items. 
  • Organizations can define acceptable  sales substitution items, and allows the sale pickers to pick substitutions as needed if the originally ordered item is not available.

Management

RFID Reader Management & Monitoring

  • Manage 1000’s of Fixed RFID readers from one cloud dashboard. Quickly sniff our reader IP’s, click to add a reader, test a reader, and start the reader. Assign each antenna to a zone.  
  • Health Alerts – Automated health check system emails when hardware issues are detected from any reader and or antenna. Tech can troubleshoot readers all from the same unified cloud dashboard. 

User Management & User Roles

  • Define User Roles, and give access to specific pages, and / or modules as desired, or simple read only access. Additionally, control what functions are possible on the hand-held RFID scanners.
  • Give users access one or more locations. Simply enter the user information, and select the user role.
  • All user activities are logged and accessible under user access logs.

Floorplan Editor

One of the easiest and most touted features Senitron is the floorplan editor function of the software. Floorplan images can quickly be uploaded, in any common image format, and next RFID readers & antenna can quickly be dragged onto the positions on the floorplan, and completed with a simple save function.

Multilocation

All of the locations for an organization can be accessed from one unified software dashboard. 

Deployment

Deployment Diagram

  • Hardware: Fixed RFID readers, RFID Printers, Hand Held RFID Printers, Tablets

Deployment Photos