The Cornerstone Solutions

To provide value to all our customers, present and future, we have combined our manufacturing ex­pertise and industry knowledge, with validated business requirements from our existing custo­mer base to build a solution focused on four key process manufacturing industry verticals:

  • Nutraceuticals
  • Life Sciences
  • Chemicals
  • Consumer Products

Solutions for Business

Leveraging proven business  processes we can provide seamlessly integrated value based solutions, which support the day today business operations and issues that are unique to the industry and enable those business to become better run process manufacturers, distributors and retailers.

As a provider of food, we have to know exactly where our inventory comes from and where it ends up so that,if there is a need to recall a given product.we can do it easily.

Thanks to the Expertise of Cornerstone Consulting we also have full control of our production processes, we know exactly what the costs of production are and can easily monitor batches of both finished and raw materials.

JoseFood Company Project Mgr

Broken down into a set of functional yet inte­grated components, our solutions cover a wide spectrum of business activities and processes:

  • Product Data Management
  • Bill of Materials/Formulations
  • Co-Product/Scrap Management
  • Routing and Resource Management
  • Batch Control and Traceability
  • Production Management
  • Ingredient Declaration
  • Quality Control
  • Complaint Management
  • Product Casting
  • Production Scheduling
  • Handheld devices & Data Collection

Industry Requirements

At the heart of the solution resides a bill of manufacturing or Formulation or Receipt. This is a concept which allows process manufacturers to define the resources that are consumed and produced as part of the production process. As a process manufacturer you need the •ease of use to define your products as simple recipes/formulas or require the flexibility of complex recipes/ formulas to define the component/ingredient relationships.

Depending on your micro-vertical industry needs and the products you produce, there are other factors which have to be taken into account for example:

  • Yield and Factor calculations
  • Co-Product and By-Products production
  • Scrap management

Variables which affect inventory levels, product costs and recipe accuracy, all of which impact the bottom line.

The market is full of process manufacturing solutions but with Cornerstone Consulitng we have a solution to strengthen our position as a contract manufacturer within this vertical, which is a competency of our business. We have a deep knowledge of manufacturing and together with our partner Cornerstone Consulting we can provide real added value to many food beverage and nutraceutical distribution companies

DonManaging Director, Contract Manufacturer

Easy Adjustment

Within every organization it is key to have systems that can be adapted to  meet  your  unique  or  changing business requirements without creating a heavy, ongoing burden. Thus each of our solutions are able to use “Core Functionality” as well as to be able to be configured or adjusted to the specific business needs.

ANALYTICS

More than ever before, Analytics are becoming one of the most critical components of any good business process.  Thus having a strong business system with scalable, configurable and Real-Time Analytics is of utmost importance. With embedded analytics and high-performance apps, the job of managing the business becomes highly efficient and thus more profitable.

The Systems and Expertise provided have become the “cornerstone” of our strategy for our Large Enterprise and SME subsidiaries. We have a strong industry focus dedicated to first-class Process Industry companies in the fields of Cosmetics, Chemicals, Pharmaceuticals and Agribusiness, just to name a few. Engaging in this process has been a significant step in bringing additional value to our customers and helping them cross the bridge between state-of-the art solutions and the business processes

EricDirector of International Business Development

Our strategy has been to focus on food and beverage, chemicals, food service and wholesale vertical markets. Focusing on the food and beverage sector, where we already have a good base of foodservice customers, meaning that we started to see an increasing number of enquiries in the food manufacturing sector. As we started to explore the available solutions, itbecameapparent that the solutions provided by Cornerstone were the only solutions in the market that offered the detailed industry required functionality whilst being both a solution that was easy to implement and use.

LindsayManaging Director

We had begun our processes, but for the next phase we were looking at business optimization especially within the areas of production and ingredient management. The Cornerstone solution provided the extra functionality required to move the business forward to another level.

RobertManaging Director

Product Data Management

The Product Data Management solution enables an enterprise to define the important elements of information and data that is required to describe a product.   Examples include:

  • Revisions with valid to and from dates
  • Phrases– to define for example phases as part of the MSDS
  • Text – to define for example hazard instructions, and safety text
  • Classifications– to categorize products for example toxic and non-toxic
  • Groups– to group similar products together for example acids and chemicals
  • Properties– to define for example physical, chemical definitions or ingredient details
  • Attachments– to reference for example MSDS, work instructions, safety sheets, production videos
  • Define default Batch and Quality Control status
  • FIFO, FEFO and FMFO batch consumption control
  • Define Shelf life and Inspection date periods
  • Batch and Serial number generation templates
  • Define Expiry warning and Expiry date calculation methods
  • Define and record a country of origin for an Item

Ingredient Declaration

An extension to product master data, this solution provides the necessary functions to define nutrient and ingredient information. Combined with allergen, percentage daily intake values and pack versus serving size, we provide the necessary data to produce ingredient listings and declaration statements to support the process of creating product labels.

  • Template –  define a list of nutrients or ingredients that are copied into the product master data to allow for quick data entry
  • Business Partner– record the business partner that supplies the ingredient
  • Specification reference– record the vendors or industry specification for an ingredient
  • Specification date– record the date of the specification
  • Classification– record details such as Halal , Kosher,  GM,  Bio,  OGM and corresponding certificates
  • Category– define a category to group like ingredients g. sugars, fats, vegetables, oils
  • Allergens– define a list of allergens and record which ingredients contain such allergens
  • Pack and Serving sizes–  define a list of pack sizes,  alternative unit of measures and corresponding serving size
  • %Daily Value– define a list of nutrient and ingredient percentage daily intake values
  • Alternative code– define common, scientific or Codex Alimentarius  INS or  EAU numbers
  • Reports– Ingredient listing, declaration statement, and percentage daily value by pack and serving size

Bill of Materials/Formulations

The Cornerstone solution provides a simple but flexible solution for creating process orientated bill of materials.

  • Items– define materials within the product structure
  • CoProducts– define a product that is usually manufactured together with another product
  • ByProducts– define material of value produced as a residual of the production process
  • Wip Items– define work in progress materials for reporting and visibility purposes
  • Scrap– define the scrap that is produced during production
  • Simple or Product Formulas– define simple or formula based relationships between materials and parent products
  • Scrap, Yield and Factors– define value and percentage uplifts for materials
  • Revision– define revision specific product structures
  • Phantoms– define phantom product structures
  • Multi-level– define multi-level product structures
  • Attachments– to define and link to detailed instructions, procedures, videos and other such media files
  • Warehouse– define the warehouse where the product is produced
  • Backflush Location– define the warehouse where material is backflushed
  • Project– define the project associated with this product for reporting purposes
  • Distribution Rule– define the distribution rule for financial transactions
  • Cost Dimensions– define the dimensions for reporting purposes
  • Issue Type– modify the picking method of inventory transaction per product
  • Mass Replace– replace selected materials and bill of materials within another material
  • Instruction tab– record specific instructions concerning Bill of Materials in a text area

 

Product Routings

Product Routings enables user to define the information required to document and define the production process.

Machine control setting and properties such as machine speed, temperature and pressure may also be defined within the routing data, allowing for data integration to MES applications and PLC’s devices.

  • Resources – define machines, labor and tooling and other such resources that are used in production
  • Operations – definition of the production activity
  • Routing – the combination of operations and resources to define the total production process
  • Properties – define additional information g. tooling settings, machine setting such as temperature, pressure, fill rate
  • Constraints – define cycle quantity throughput, number of similar machines, and operation to operation overlap with percentages
  • Production time – define queue, set-up, run time, and stock time, each with a different rate of measure g. fixed hours, minutes per unit, units per second
  • Attachments – to define and link to detailed instructions, procedures, videos and other such media files
  • Calendar – define production and resource calendars
  • Resource Accounting – define account codes for resource, fixed and variable overhead financial postings
  • Alternative Routings – define for a product alternative routings
  • Material Operation – link the consumption and production of materials to process operations

Product Costing

Product Costing has been built to provide a solution which supports the costing, analysis and finance controlling operations.
  • Methods – Standard, Moving Average, FIFO
  • Revision – calculate the cost of a product on a revision basis
  • Flexibility – cost products based upon a combination of costing methods
  • Costing Calculation – based on manual, price list, and calculation
  • Factors – include scrap, yield and factors within costing roll-ups
  • Cost Categories – define cost category for valuation, what-if simulation and analysis
  • Types – define material, resource and labor costs
  • Time – define different costs for the elements of production time, queue, setup, runtime and stock
  • Overhead – define fixed and variable overheads as a value or a percentage
  • Cost allocation – proportion production costs across products, coproducts and byproducts
  • Product analysis – calculate and review costed bill of materials and routings
  • Visibility – pre, during and post calculation
    of manufacturing order costs
  • Variances – calculate and manage costing variances
  • General Ledger – define additional costing accounts by product group and warehouse
  • Advanced G/L Account determination functionality supported

Manufacturing Orders

Manufacturing orders are used to plan, execute and record production activities.

  • Order dependentrecipe/formulation and routings–allows forthemodificationoftheproductstructureandproductionprocesstomanageeverydaychangesthatmayoccurwithinproductionratherthanchangingcompanystandards
  • Method of creation–manually, via Sales Order, Forecast, MRP and Sales Order back-to-back
  • Record–manage material issues, Product, CoProduct and Scrap receipts
  • Revision–createmanufacturingordersthatarerevisionspecific
  • DemandAllocation–linkasingleormultipleSalesOrderstoproductionsupplyorders
  • Dates–entertherequired,plannedstartandplannedenddatesandtime
  • Schedule–forwardorbackwardstocalculatetheplannedstartorplannedenddateandtime
  • Warehouse–thedefaultwarehousewhereproductionwilloccur
  • BinLocations–pickingandreceiptofinventorybasedonbinallocationrules
  • PlannedvsActualQuantity–monitortheorderanditemquantitystatus
  • Quality–conductqualitycontrolprocesses
  • MaterialShortage–checkavailableandshortagesofstockwithinplannedwarehouseandacrossallwarehouses
  • Traceability–reviewallthedocumentsassociatedwithpickingandreceivinginventory
  • IssueType–alterinventoryissuesmethodsfrommanualtobackflushandviceversa
  • OperationTimes–reviewoperationtimesandoverlaps
  • Reporting–reportonthestatuschangeofoperationsandrecordactualproductiontime
  • Analysis–reviewactualvsplannedmaterials,time,costsandvariances
  • DocumentStatusChangeWizard–changeanumberofdocumentsstatuswithinfewseconds
  • Instructiontab–recordspecificinstructionsconcerningManufacturingOrderinatextarea

Backflushing

The Cornerstone solution provides flexible back-flush methods to meet the  diverse needs of manufactures. This flexibility is based on the Bill of Material and Routing which allows for product by product configuration of what and where is back flushed. While at a Manufacturing Order level can cater for temporary changes in inventory picking processes. Methods include:
  • Materials
  • Co-Products
  • By-Products
  • Scrap
  • Warehouse and Bin location
  • Batch trace materials–based on a FIFO basis
  • Resources–machine and labor time

Production Scheduling

Based upon a number of resources and time constraints, we provide a simple but powerful scheduling solution to manage the manufacturing orders within the plant and to manually reschedule via “drag and drop” means. The solution also automatically backward schedules sales orders that are converted to manufacturing orders on a back-to-back basis to determine the start and end date and time, based on the sales order delivery date. Manufacturing orders generated from MRP are also automatically scheduled when created.
  • Direction – Forward and Backward scheduling methods
  • Overlapping processes – define overlapping quantity between operations
  • Color status bar – to identify manufacturing orders by Scheduled, Released and Started status
  • Display time types – color coded setup and production run times
  • Drag and Drop – move manufacturing orders forwards and backwards and move or split across alternative resources and view the impact of available capacity
  • Tooling – review relationship between machine and tooling
  • Alternative resources – define and select alternative resources, and view the time impact
  • Variable rates of time – define for setup and runtime fixed time, units per time and time per unit
  • Stock and Queue times – define stock and queue time between operations, for example cooling down time
  • Resource units – define the number of similar resources
  • Capacity view – view detailed capacity profile for a selected resource
  • Cycle production – manage material throughput via fixed batch sizes to reflect quantity based constraints for example ovens, mixing vessels, kilns and freezers
  • Calendars – define and manage capacity calendars for each resource, with shift patterns, exceptions such as downtime and company holidays
  • Dual resource scheduling – schedule machines and multiple tools availability constraints at the same time
  • Scheduling Advanced relations – a possibility to create advanced, non-linear relations between operations in a Manufacturing Order
  • Resource Planning Board – control Resources used in production process from a Gantt chart level
  • PDC Statuses – statuses of Operations recorded in PDC (work time registration application) available from a Gantt Chart level
  • Clarity – possibility to mark all operations from specific Manufacturing Order on Gantt Chart

Batch Control and Traceability

Cornerstone’s Batch Control and Traceability functions provide the necessary process and controls to trace the genealogy of a product. While control functions manage the day to day operations of working with traceable products.
  • Batch and Serial Number – define number formats and counters
  • Supplier Batch Number – record suppliers batch number details
  • Shelf Life – define the life period of a product in days and hours
  • Expiry or Consume control – define batch management policy
  • Expiry/Consume by Date – manual or calculated date based on shelf life period
  • Inspection date period – define the period between inspections
  • Inspection dates – manual or calculated dates for future inspection dates
  • Warning inspection and expiry date – define the warning period for batch review
  • Product Revision – revision code recorded within the batch data
  • Batch properties and values – properties inherited from Product Master Data
  • Quality control results – actual test result values stored against batch properties
  • Batch genealogy tree – forward and backward historical view
  • Recall and Audit Report – list of customers and batch recall reconciliation
  • Drill down – transaction and document traceability navigation
  • Inventory and Batch reports
  • Complaints – check the Batch related Complaint documents
  • Inventory – Batch Items distribution through Warehouses and Bin Locations, broke down into: Existing Quantity, Allocated Quantity, Available Quantity
  • Attachments – browse through and add attachments to the specific Batch. Attachments can be assign to a specific Business Partner
  • Returns – check Returns connected to a specific Batch from Additional Batch Details level
  • Best Before Date – record a usability period of Batch Items

Quality Control

The Quality Control solution provides the tools and processes to manage the quality process from purchase goods receipt to customer delivery.
  • Test Protocol – define standard templates to be used within the quality control process
  • QC Test – record the activity and results of the tested properties
  • Status and Date – manage the QC test cycle
  • Non-Conforming Materials Report – record specific actions and generate report
  • Inspectors – define individuals performing QC activities
  • Reason/Defect Codes – define analysis codes and groups to provide structured data for analysis and reporting purposes
  • Resources – define the resources to perform the testing e.g. microscope, x-ray machine, weight scales
  • Items – define the materials that are required to perform the test e.g. gloves, safety glasses
  • Frequency – define the frequency and method of testing
  • Transactions – define the process point where the QC test will be performed
  • Alerts – business alerts to communicate to inspectors when tests are required to be performed
  • Instructions – define instruction steps for performing the test or recording additional notes
  • Attachments – to define and link to detailed instructions, procedures, videos and other such media files
  • Warehouse – define tests for specific warehouse
  • Project – define tests as part of a project
  • Analysis – dashboard and reporting
  • Quality Control Tests Statuses – Pass/Fail/Not Applicable
  • Record Multiple Test Results option – Passed/Failed status on Quality Control Test, Test Results tab can be determinate by Passed/Failed ratio of multiple test records

Complaint Management

Normally a function of the Quality Control department, the Complaint Management solution is an end-to-end business solution, which provides a structured method in capturing and managing the life cycle of a complaint regardless if the origin is from a customer, vendor or an internal department.
  • Complaint number – reference number for tracking activity
  • Complaint type– record the source of the complaint: Customer, Supplier or Internal
  • Complaint codes– define reason codes and groups to provide structured data for analysis and reporting purposes
  • Status and date– manage the complaint cycle
  • Sample tracking – track the progress of customer and supplier sample returns
  • Transactions – record the transaction type and number provided by the complaint
  • Batch number– search and record the batch numbers
  • Serial numbers– search and record the serial numbers
  • Batch Traceability– perform batch trace visualization
  • Notes and attachments– record extensive notes and link attachments
  • Quality control– create and link a quality control test to the complaint
  • Product Recall– flag the complaint as a basis for a product recall
  • Dashboard and reporting

Data Collection

To improve the accuracy of data and to streamline production and inventory process flows this solution
provides a fully integrated data collection and label printing solution. Thanks to it you can collect data
directly in a warehouse:
  • Goods receipt from purchase order* – record goods inwards inventory based on a purchase order
  • Goods receipt* – record goods inwards inventory not based on a purchase order
  • Stock transfer* – inter-warehouse inventory transfers
  • Pick order – pick inventory for manufacturing orders
  • Pick receipt – record products, coproducts, byproducts and scrap inventory produced during the production process
  • Delivery* – manage items going out of the warehouse to an external destination
  • Storage Units – a number of functions that allows to easily manage different types of storage units, e.g. creation of multilevel storage units (e.g. managing a number of boxes of items within a pallet), bulk storage unit creation, split or disassemble storage unit
  • Stock Counting* – perform stock counting directly from a warehouse
  • Pick & Pack* – Pick & Pack process
  • Document Drafts* – create a draft document on a device to be added by supervisor or just to finish it later
  • Informational features – an instant access to information about warehouses, bins, batch and serial numbers, storage units
  • Barcodes – an integration with barcode scanning devices
  • Labels – define label layouts and required data, integrated with Crystal, Zebra and other label printing software.

Customization

The Cornerstone supplied solution has been developed to take advantage of the User Defined Objects methodology. Based on this development technique Cornerstone forms and transactions behave in the same manner as forms developed by SAP.
Therefore partners and customers can create additional value added enhancements to solve implementation specific requirements using standard customization tools.
  • Behavior & Navigation
  • Use existing features & functions
  • Minimal application footprint
  • User defined fields
  • Formatted searches
  • Document numbering
  • Permission model
  • Licensing model
  • Crystal Reports Print layouts
  • Transaction notification
  • Field label changes

Translation

Utilizing a SaaS based Translation tool, integrated with Google’s Translate API, the User Interface ( menus, forms, dropdown lists and system messages), are available in a wide variety of languages. This simple but effective tool speeds up the activity of translating. From a partner perspective, with ease of change and testing directly on their local machine, and for immediate update into the application architecture within the development lab. When functional enhancements are added to existing forms, the user can filter to view fields with no Translator. Therefore saving time in having to search through all the forms fields to locate empty translations.

Contact us Today to see how Cornerstone can Help

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