ANTARA - SYSTEM FOR TANNERIES ANTARA is an ERP system developed specifically for the leather industry, which has been successfully attending small, medium and large tanneries around the world, for more than 24 years, with proper tools for this particular business. Developed by the Brazilian company “SystemHaus”, located in Novo Hamburgo - RS, ANTARA is a software specially adapted to control the most diverse scenarios in the leather production, providing accurate information on the main production indicators of a tannery and providing easy and effective planning tools, resulting in fast responses and effective results in just few months after its implementation.
Layout Solution Antara
Main Features of Antara
SCHEDULING LEATHER PRODUCTION Production scheduling is a complex task in a tannery. Often, fictitious delivery dates are given to customers due to the complexity of scheduling without an appropriate tool. Generic systems are unable to provide a reliable scheduling, since they are not prepared to consider the specific variables in a leather production process. Knowing this reality, Systemhaus has dedicated years of research with professionals who know deeply leather manufacturing process and production scheduling techniques to develop a production scheduling module, which considers characteristics of each tannery department, such as: - Drum scheduling, considering the capacity of each drum in kilograms and the recipe total time, with the possibility of scheduling multiple rounds during the day - Possibility of scheduling by machine/work center, defining the unit of measurement for the scheduling( area, pieces, weight or minutes) - Milling drums scheduling, considering load time, process time and unload time, according to the standard times - Restrictions by tonality for work centers, which are able to work only with specific tones, such as a spray or drum for light colours only - Restrictions by animal type, for companies that manufacture leather from different animals and also have specific machinery for each type - Production scheduling by considering machines that work in a line, e.g., setting out machine, vacuum and hang drying - Production routes that enable the scheduling of one order in different companies within the group. Beyond these features that make Antara a tool for production scheduling in tanneries, the usability of the system is friendly and it has tools that provide an easy and fast way to schedule and reschedule production orders, saving time spent in this process.
The result of this specialization can be seen in practice: in some medium-sized tanneries, rates of delivery on time have increased from 30% to over 95% after three months using Antara’s scheduling module: a result that undoubtedly changes the image of the tannery to its customers, becoming an important competitive differential. YIELD - MAIN KEY PERFORMANCE INDICATOR During production, hides are submitted to various physico-mechanical actions and, as a consequence, the area changes. This variation is named Yield, and it has a direct impact on the final cost of the article. If one production order has a loss of yield higher than expected, its cost will be higher as well and the final production order result could be jeopardized. When this happens, it’s essential to analyze the process and identify the reasons that caused the unexpected yield loss, and take appropriate actions to fix the problems in order to avoid the same thing happening again. Yield analysis provides an overview about the efficiency and standardization of the production process. A structured tannery defines yield targets for each article and follows up actual results. A higher loss of yield than the average shows process inefficiency, while large oscillations show a lack of standardization within the production process. However, it’s not simple to control yield. In a practical way, one production order can be subdivided in other production orders for different customers during the process or it can have some hides picked up for sampling or testing. Thus, if the ERP doesn’t have a total traceability control, not all the useful information is available, and someone will be spending a lot of time trying to organize a reliable report. Using Antara, managers can follow all sub-divided production orders to get reliable yield reports, rejects statistics, reasons for rejects, quantity of trimmings, etc. All these functionalities allow the evaluation of process efficiency and support the decision making process in order to minimize losses and maximize profits.
UPTIME AND EFFICIENCY - IMPROVING SHOP FLOOR PERFORMANCE: Improving shop floor performance is possible when all problems and bottle necks are known. Using Antara, it is possible to have a clear picture of the reasons that are affecting results and also how to have improvements at bottle necks. To collect data Antara uses barcode readers installed in shop floor, where operators input information about all the steps executed in production, including quantities, times, downtimes and reasons for the downtimes. The comparison of execution times against standard times gives the percentage of efficiency for each machine. Also, the comparison of worked time against available time over a period of time for each machine displays the uptime percentage. Using Antara, it is possible to control these two variables. The program helps to measure key performance indexes and to identify and act where the indices are below that expected. Based on it, Antara can provide production performance increments and also help on decreasing operational costs.
PURCHASE PLANNING BASED ON PRODUCTION SCHEDULE AND ITS EFFECTS ON CASH FLOW: Planning raw material purchases has a direct impact on stock level and also on cash flow. Purchasing the wrong product may result in storing them for months hence creating an imbalance in cash flow followed by financial cost for having unused products in stock.
Antara helps to solve this issue using a tool called "Future Stock", which provides an overview about all raw materials needed to supply scheduled sales order, the stock available and the expected wet blue selections. This information gives a “picture” of the stock, highlighting the selections which are missing or abounding. Using this tool, it is possible for tanneries to plan raw material purchases in the right way or to redirect some sales based on raw material availability. INTEGRATED COST - COST ANALISIS SOLUTION An effective cost analysis needs a practical and reliable tool which shows where to act to have immediate results. The Costs Module in Antara is designed to show clearly all incidences of cost in a production order, step by step during production execution: raw material, chemicals, operational costs, subcontracting. It considers also the cost recovery with byproducts, the losses with rejects, reworks and its impact in the operational cost. This tool allows the tannery to see the real profit by article and it is also a potential tool for sales price formation.
SUCCESS IN SMALL, MEDIUM AND LARGE TANNERY BUSINESSES Being a practical and flexible tool, Antara is the ideal tool for all tanneries. Antara works very well in big companies with branches or plants spread worldwide where it is necessary to implement a multi-plant control using all Antara’s functionalities, as well as in small companies, where it’s possible to implement the system in a modular way, starting from modules which will bring immediate benefits and further on implementing complementary modules.