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Real-Time Work-in-Process and Materials Tracking Systems

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Optional BellHawk Software Modules

The software for a BellHawk system consists of a base WIPS, BITS, or JMTS system plus optional modules which are listed below.  The base BellHawk systems have a wide range of capabilities but, depending on the specific application, clients may need to add the following modules. 

The Warehouse Management System (BH-WMS) discount bundle adds the BH-PO, BH-PICK, and BH-SO options to the base BITS or JMTS system to create a fully featured solution for industrial warehouse management.

Manufacturing Options

Equipment Tracking Option (BH-ETO): This module tracks the setup, run, down, and cleanup time for equipment, machines, and production lines. It also tracks the reasons that machines are down.

Activity Based Job Costing (BH-ABC): Computes the cost of jobs and batches based on the labor and materials consumed in the production of materials. Compares planned versus actual at the job step and batch level. Can be used as the basis of exporting cost data back to ERP systems.  This module allocates labor, machine time and materials across the various jobs that are running at the same time on a machine or production line.

Warehouse Management Options

Purchase Order Receiving Module (BH-PO): Enables the entry or import of supplier purchase orders (POs) or advanced shipment notice data for the receipt of customer owned materials. Produces POs that can be sent to suppliers by mail or Email and also barcoded receiving documents. Tracks and records receipt of materials against POs. Please note that simple receiving of materials is included in the base BellHawk OTS system.

Ship Order Module (BH-SO): Enables the entry or import of customer ship orders. Includes capability to generate Make-to-Order work orders from ship order lines. Can be used to recursively generate work orders and purchase orders for make-to-order items when used in conjunction the demand based materials planning (BH-DMP) module. Can also generate a barcoded picking sheet to record picking and packing of materials for a customer order when used with the BH-PICK module. Please note that simple shipping of materials is included in the base BellHawk OTS system

Picking Module (BH-PICK): Enables entry and tracking of material picking and move orders. Produces and uses a barcoded picking sheet for recording the picking, packing, and movement of materials. Enables material handlers to easily find materials and pick oldest materials first. Also checks that they are picking correct materials for move order. PICK can also be used to generate pick tickets to pick materials needed for route steps in manufacturing orders and to record the picking, packing and shipping of customer orders, when used with the SO module. This picking module is designed to make it easy for material handlers to handle a number of different types of pick orders in a uniform manner.

Shipping Dock Option (BH-SDO): Tracks loading of customer orders onto trucks/trailers at a shipping-dock. Warns material handlers if they attempt to load pallets or other shipping containers onto the wrong truck. Gives shipping supervisors visibility of what has been loaded. Sets up data to generate Bills of Lading and data for Advanced Shipment Notices. Requires the use of the SO and PICK options.

Inventory Auditing (BH-IAM): Enables auditing inventory without shutting down operations. Enables recording inventory on a location by location basis. Produces inventory discrepancy report and tracks actions by materials manager to resolve discrepancies. Supports "blind" inventory auditing. Automatically resolves discrepancies for inventory that has "walked".

Materials Traceability Options

Materials Traceability (BH-TRACE): Builds electronic materials traceability database. Tracks what materials from which suppliers and lot numbers went into each product, enabling rapid trace-back from defective products to source components and their suppliers. Also gives ability to trace forward to find all products that may be defective as a result of defective source or intermediate materials.

Quality Assurance (BH-QC): Tracks quality control status of inventory and work-in-process and prevents use or shipment of defective materials. Allows quality department to pass or fail materials with recording of reason codes. Handles lot-based and statistical inspection. Tracks movement of materials needing inspection and prevents movement to non-quarantine locations. Also tracks materials needing material review activities.

Operations Management Options

Project Tracking (BH-PROJ): Allows purchased and produced materials, as well as jobs, to be assigned to projects. Warns users if they attempt to mix materials from different projects or to use materials from a different project on a job. Allows filtering of inventory reports by project. Also shows status of all POs, work orders, and ship orders for project in one unified Excel export.

Available Inventory Prediction (BH-AIP): Predicts available inventory levels at future times taking into account materials in stock, on order, and scheduled to be produced and consumed on work orders. Requires SO and PO modules. This performs the complex calculations needed for materials requirements planning (MRP) but leaves the decisions as to what parts to make or materials to order to the user, which can be ideal for make-to-order manufacturers.

Demand Based Materials Planning (BH-DBP): works in conjunction with Available Inventory Prediction module (BH-AIP) to enable the recursive generation of work-orders and purchase orders for make-to-order sales order line items.  Unlike fully automated MRP (Materials Requirements Planning) system this enables production managers to interactively make decisions as to what to make or buy and when in order to fulfill make-to-order requirements from their customers. These decisions are guided by the real-time prediction of the available inventory enabling incremental planning for each customer order as it is received.

Technology Options

Rules Based Barcode Labeling (BH-TAG): Automatically generates labels for incoming materials and for finished product packaging. These labels have a unique tracking barcode plus user specified information in human readable format. Enables automatic generation of labels for products and labels in client specific formats. Eliminates mistakes from manual entry of data for generating labels. Integrates with BarTender Automation from Seagull Scientific for label layout and printing labels on a wide range of barcode label printers and RFID tag encoders.

For more information please download Data Sheets for the base systems and the optional modules.

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