ERP Success Starts with the Right Implementation.
​
Choosing the right ERP system is only half the journey. Even the most powerful ERP software can fail if it’s poorly implemented.
​
Missed requirements, lack of training, or unrealistic timelines often lead to cost overruns, low adoption, and operational disruption.
The good news? Most ERP implementation failures are entirely preventable.

By understanding the most common mistakes and planning correctly, businesses can ensure a smooth transition and long-term success. In this Blue Sky ERP article learn the most common ERP implementation mistakes and how to avoid them.

​Mistake #1: Not Defining Clear Business Requirements
One of the biggest causes of ERP failure is jumping into implementation without clearly defined goals.
Common issues include:

• Unclear expectations
• Over-customisation
• Choosing features that don’t support real workflows

How to avoid it:
Start with a detailed discovery phase. Identify pain points, priority processes, reporting needs, and future growth plans before implementation begins.

Mistake #2: Lack of Executive Sponsorship
ERP implementation impacts the entire organisation. Without leadership support, projects lose momentum and accountability.

How to avoid it:
Ensure senior stakeholders are actively involved, aligned on objectives, and visible throughout the project lifecycle.

​Mistake #3: Underestimating Change Management
ERP introduces new processes, new systems, and new ways of working. Resistance to change can derail even the best technical implementation.

How to avoid it:

• Communicate early and often
• Involve users from day one
• Provide role-based training
• Set clear expectations about benefits and outcomes

Mistake #4: Poor Data Migration Planning
Data migration is one of the most complex stages of ERP implementation. Incomplete or inaccurate data leads to reporting issues and user frustration post go-live.

How to avoid it:

• Clean and validate data before migration
• Map legacy data carefully
• Test migration multiple times
• Avoid migrating unnecessary historical data

Mistake #5: Inadequate Testing
Skipping or rushing testing is a costly mistake. Errors discovered after go-live are far more disruptive and expensive to fix.

How to avoid it:
Conduct:

• System testing
• Integration testing
• User acceptance testing (UAT)
• End-to-end process testing

Testing ensures confidence and stability before launch.

​Mistake #6: Choosing the Wrong Implementation Partner
ERP is not a “plug-and-play” solution. The expertise of your implementation partner is critical.

How to avoid it:
Choose a partner who:

• Understands your industry
• Offers structured implementation methodology
• Provides ongoing support and optimisation
• Focuses on long-term success, not just go-live

Blue Sky ERP combines technical expertise with real-world business understanding to guide clients through every stage.

​Mistake #7: Rushing the Go-Live
Pushing for a fast go-live without readiness often leads to operational disruption and poor user adoption.

How to avoid it:
Adopt a phased rollout approach where appropriate. Ensure teams are trained, confident, and supported before full deployment.

​How Blue Sky ERP Helps You Avoid These Mistakes
​
Blue Sky ERP takes a structured, proven approach to implementation, including:

• Detailed discovery and planning
• Industry-aligned best practices
• Data migration and testing support
• User training and change management
• Post-go-live optimisation and support

Our goal isn’t just to implement ERP, it’s to ensure your system delivers long-term value.

​Conclusion: Plan Right, Implement Once
ERP implementation doesn’t have to be risky. With the right planning, partner, and approach, ERP can transform how your business operates.

Ready to implement Epicor ERP with confidence?
Let Blue Sky ERP guide your ERP journey from day one. Book a free implementation consultation with our team today.


​​FAQs: ERP Implementation

What is the most common ERP implementation mistake?
Lack of clear requirements and poor change management are the most common causes of ERP failure.

How long does ERP implementation take?
Cloud ERP implementations typically take weeks rather than months, depending on scope and complexity.

How do you prepare for an ERP implementation?
Define objectives, involve stakeholders, clean data, plan training, and choose an experienced implementation partner.

Why does ERP implementation fail?
Failures usually stem from poor planning, insufficient training, lack of leadership support, or unrealistic timelines.
​
Can a good ERP partner reduce implementation risk?
Absolutely. An experienced partner like Blue Sky ERP provides structure, guidance, and ongoing support to ensure success.

Choosing ERP Is a Business-Critical Decision.

Selecting an ERP system is one of the most important technology decisions a business can make. The right ERP improves efficiency, visibility, and scalability. The wrong one leads to poor adoption, rising costs, and operational disruption.
​
This guide walks you through how to choose the right ERP system, what to look for, and how to avoid common mistakes, especially for small and mid-sized businesses.

​1. Signs Your Business Is Ready for ERP

You may be ready for ERP if:

• You rely heavily on spreadsheets
• Finance, sales, and operations use disconnected systems
• Reporting is slow or inaccurate
• Manual processes are causing errors or delays
• Growth is creating operational complexity

ERP centralises your data and processes, replacing fragmented tools with one integrated platform.

2. Define Your Business Requirements First

​Before looking at vendors, identify:

• Core processes you want to improve (finance, inventory, reporting, CRM)
• Current pain points and inefficiencies
• Regulatory or compliance requirements
• Integration needs (CRM, BI, payments, banking)

Clear requirements prevent overbuying and ensure ERP fits your actual needs.

3. Choose Cloud ERP for Flexibility and Scalability
​
For most modern businesses, cloud ERP is the preferred choice.

Benefits include:

• Lower upfront costs
• Faster deployment
• Automatic updates
• Remote access
• Built-in security and compliance

Cloud ERP, such as Epicor Kinetic from Blue Sky ERP, allows your system to scale as your business grows, without expensive infrastructure upgrades.

4. Prioritise Industry Fit and Modularity

One-size-fits-all ERP systems often include unnecessary complexity.
​
Look for:

• Industry-relevant functionality
• Modular design (only pay for what you need)
• Configurable workflows rather than heavy customisation

Blue Sky ERP offers modular, industry-aligned Epicor ERP solutions designed for growing organisations.

5. Ensure Strong Integration Capabilities

Your ERP should connect seamlessly with:

• CRM platforms (e.g. HubSpot)
• Business intelligence tools (e.g. Power BI)
• Banking and payment systems (e.g. BACS)

Integration eliminates data silos and provides end-to-end visibility across the business.

6. Understand Total Cost of Ownership (Not Just Price)

ERP costs extend beyond licences. You need to consider:

• Implementation and onboarding
• Training and support
• Ongoing maintenance
• Scalability costs

Cloud ERP typically offers a lower total cost of ownership than legacy systems.

7. Evaluate Implementation and Support

Successful ERP adoption depends on:

• Clear implementation methodology
• Experienced consultants
• Ongoing support and optimisation

ERP is not just software, it’s a long-term partnership.

8. Why Blue Sky ERP Is the Right Choice

Epicor ERP from Blue Sky ERP provides:

• Cloud-based, scalable ERP
• Industry-specific and modular solutions
• Seamless CRM, BI, and BACS payment integration
• Expert UK-based implementation and support

Ready to take the next step? Book an expert consultation with Blue Sky ERP today.


FAQs: Choosing the Right ERP

​How long does ERP implementation take?
Most cloud ERP implementations take weeks rather than months, depending on scope and complexity.

Is ERP suitable for SMEs?
Yes. Modern cloud ERP is designed specifically for SMEs looking to scale efficiently.

Can ERP integrate with my existing systems?
Yes. ERP platforms like Blue Sky’s Epicor ERP integrate with CRM, BI, and banking systems.
​
What mistakes should I avoid when choosing ERP?
Choosing based on price alone, ignoring scalability, and underestimating implementation support.


By Neil Jones
Director at Blue Sky ERP, over the last decade Neil has worked with over 80 Epicor ERP customers across various sectors from aerospace, marine, distribution, agricultural, telecommunications and automotive.

 The next evolution of ERP

As we move towards the end of 2025, Enterprise Resource Planning (ERP) systems are no longer just back-office tools,
​they’re the backbone of digital transformation.

With emerging technologies like AI, automation, and advanced analytics reshaping industries, modern ERP solutions
are smarter, more agile, and more connected than ever before. 

Here’s a look at the top trends in 2025 that are redefining how businesses operate, and how you can stay ahead of the curve.

1. Cloud ERP Dominates the Market
The shift to the cloud continues to accelerate in 2025. Businesses of all sizes are embracing cloud ERP to reduce IT costs, increase scalability, and gain anytime-anywhere access.
Unlike traditional on-premise systems, cloud ERP offers flexibility, automatic updates, and real-time collaboration across departments
​and geographies.
With Blue Sky ERP’s cloud-based Epicor platform, Kinetic, your business can future-proof operations without heavy infrastructure investment.

2. AI-Driven Analytics and Automation
Artificial intelligence is transforming ERP from a reactive tool into a predictive business engine.
Expect to see:

• Predictive analytics that forecast sales, demand, and inventory.
• Automated workflows reducing human error and freeing teams for strategic work.
• Intelligent recommendations based on historical data and business trends.

AI-powered ERP systems won’t just track your operations, they’ll help guide your decisions.

3. Mobile ERP and Remote Access
The modern workforce is mobile, and ERP is following suit.
Mobile ERP applications empower teams to access dashboards, approve requests, and manage workflows on the go.
Whether your staff is in the office, on the factory floor, or visiting a client site, mobile ERP ensures productivity never stops.

4. Industry-Specific ERP Solutions
In 2025, one-size-fits-all ERP is a thing of the past.
Businesses are adopting industry-tailored ERP systems that address unique challenges — from compliance in manufacturing to project costing in construction or service-based businesses.
Blue Sky ERP provides configurable modules designed for specific industries, ensuring functionality aligns perfectly with operational needs.

5. Integration with BI and CRM Tools
ERP no longer operates in isolation. Integration with Business Intelligence (BI) and Customer Relationship Management (CRM) tools is now essential for holistic visibility.
Solutions like Power BI and HubSpot CRM integrated with Epicor ERP from Blue Sky ERP create a seamless flow of data, empowering leaders with end-to-end insight —​ from marketing and sales to delivery and finance.

6. Focus on Sustainability and Compliance
Sustainability is becoming a business imperative.
ERP systems are evolving to help organisations track carbon emissions, manage resource efficiency, and maintain compliance with ESG (Environmental, Social, and Governance) standards.
Expect to see dashboards and analytics tools built directly into ERP platforms for tracking sustainability KPIs.

7. Enhanced User Experience (UX and Presentation
Gone are the days of complex, clunky ERP interfaces.
In 2025, ERP systems are embracing modern UI design, personalised dashboards, and role-based access, making systems more intuitive and user-friendly for all levels of staff.

Conclusion: The Future of ERP is Smart, Cloud-Based and Connected.

ERP is no longer just an operations tool, it’s a growth enabler.
Businesses that adopt modern ERP solutions in 2025 will be better equipped to handle change, harness data, and achieve operational excellence.

Future-proof your operations with Blue Sky ERP’s Kinetic cloud-based platform.
Contact our team and book your free demo.


FAQs: Top ERP Trends in 2025

1. Why are cloud-based ERP systems growing so quickly in 2025?
Cloud ERP offers scalability, flexibility, and real-time access, making it ideal for modern, distributed teams.
​With automatic updates and reduced IT costs, it’s the most efficient way to manage business operations.

2. How does AI improve ERP performance?
AI-driven ERP systems provide predictive analytics, automate routine tasks, and deliver insights to support smarter decision-making.
This helps businesses optimise resources and anticipate challenges before they arise.

3. What industries benefit most from ERP in 2025?
Manufacturing, distribution, construction, and service-based industries all see major benefits — especially with tailored Epicor ERP solutions that address sector-specific workflows.

4. How can ERP support sustainability goals?
Modern ERP platforms include features to monitor energy consumption, manage resources, and track compliance with environmental standards, helping organisations meet ESG objectives.
​
5. How do I choose the right ERP system for my business in 2025?
Focus on flexibility, integration capabilities, user experience, and scalability. Cloud-based systems like Kinetic from Blue Sky ERP offer future-ready functionality to adapt as your business evolves.
 
Discover how Epicor ERP from Blue Sky ERP can boost your business operations
Visit our Epicor ERP Overview page and schedule a call with our expert team to transform your business.​

In today’s competitive manufacturing industry, efficiency isn’t just an advantage - it’s a necessity. From managing complex supply chains to maintaining quality standards and meeting customer expectations, manufacturers face challenges that can overwhelm outdated systems and spreadsheets.

That’s where Enterprise Resource Planning (ERP) software for manufacturing comes in.
​Epicor ERP provides a central hub to manage your operations, giving you visibility, control, and the ability to scale with confidence.

What Is Manufacturing ERP?
Manufacturing ERP is a business management system tailored to the needs of manufacturers. It integrates all the core functions you rely on - production planning, inventory, procurement, quality control, finance, and customer service into one platform.

Instead of juggling disconnected tools, ERP lets you manage everything from raw material orders to finished product delivery in real time.

Key Benefits of Epicor ERP for Manufacturing:

1. Smarter Production Planning
ERP systems align demand forecasting with production schedules, so you produce the right quantity at the right time. This reduces downtime, prevents overproduction, and helps balance workloads across shifts.

2. Real-Time Inventory Management
Manual stock checks are prone to errors. Epicor ERP tracks raw materials and finished goods automatically, so you always know what’s available. This prevents stockouts, reduces waste, and ensures smooth production.

3. Improved Quality Control
Consistent product quality is vital in manufacturing. Epicor ERP helps you set quality standards, monitor processes, and track nonconformance reports - so defects are caught early, not after reaching customers.

4. Cost Reduction
By automating workflows, reducing errors, and providing real-time cost tracking, ERP software lowers operational expenses. Manufacturers often see savings in procurement, labour efficiency, and material usage.

5. Better Customer Service
Epicor ERP provides end-to-end visibility, meaning you can respond to customer inquiries faster, give accurate delivery timelines, and ensure on-time shipments.

​Cloud ERP for Manufacturers
Modern manufacturers benefit most from cloud-based ERP solutions like Kinetic Epicor ERP from Blue Sky ERP. Cloud ERP offers:

• Scalability – Add users, locations, or modules as your business grows.
• Accessibility – Access production data anytime, anywhere - even on the shop floor.
• Lower IT Costs – No expensive servers or in-house maintenance required.
• Automatic Updates – Always stay current with the latest features and security.

Why Choose Blue Sky ERP?
At Blue Sky ERP, we understand the unique challenges manufacturers face.
Our Kinetic Epicor ERP solution helps small and mid-sized manufacturers:

• Optimise production scheduling
• Reduce material waste
• Improve compliance and reporting
• Connect shop floor operations with back-office functions
• Gain real-time insights through Power BI dashboards

With Blue Sky’s Epicor ERP, you don’t just get software - you get a partner dedicated to making your manufacturing operations more efficient, profitable, and scalable.

​FAQs About ERP for Manufacturing

1. What is the difference between ERP and MRP in manufacturing?
MRP (Material Requirements Planning) focuses mainly on materials management and production scheduling. ERP, on the other hand, is broader - it includes MRP functions but also integrates finance, HR, CRM, and supply chain into one unified system.

2. Is ERP only for large manufacturers?
No. Modern cloud ERP solutions are designed to be cost-effective and scalable, making them ideal for small and mid-sized manufacturers. Blue Sky ERP offers modular solutions that grow with your business.

3. How long does it take to implement ERP in a manufacturing business?
Implementation timelines vary based on company size and complexity. Smaller manufacturers can often be up and running in a few months, while larger operations may take longer. With expert guidance from Blue Sky ERP, the process is faster, smoother, and less disruptive.

4. What ROI can manufacturers expect from ERP?
Most manufacturers see ROI through reduced operational costs, better resource utilisation, improved compliance, and increased customer satisfaction. A well-implemented ERP can pay for itself within 1–3 years.

5. How does cloud ERP improve shop floor operations?
​Cloud ERP like Blue Sky’s Kinetic Epicor ERP solution provides real-time data access directly on the shop floor. Teams can monitor production, update job statuses, and access inventory levels instantly - helping reduce errors and downtime.
​

Ready to Transform Your Manufacturing Operations?
Don’t let outdated systems hold back your production. Blue Sky’s Epicor ERP for manufacturing can help you cut costs, improve efficiency, and deliver better results.

Book a call with Blue Sky ERP and see how we can help your manufacturing business grow.
​

By Leroy Meares
Director at Blue Sky ERP with over 8 years’ experience in ERP Implementations and upgrades, specialising in Epicor 9 and Epicor 10.
Core skills include SQL, C# and Service Connect.

In today’s fast-paced, digitally driven economy, businesses face mounting pressure to do more with less. From managing finances and inventory to customer relationships and HR, juggling multiple disconnected systems often results in errors, wasted time, and poor visibility.
 
This is where Enterprise Resource Planning (ERP) software comes in. Epicor ERP software unifies your business operations into one central platform so your teams can work smarter, not harder.
 
What Is ERP Software?
ERP software is a business management tool that integrates essential functions like accounting, sales, supply chain, human resources, and customer service into a single, easy-to-use system.
 
Instead of switching between spreadsheets or siloed applications, Epicor ERP gives you real-time access to accurate data across departments, so you can make faster, smarter decisions.
Think of ERP as the digital backbone of your business - connecting people, processes, and data to drive growth and efficiency.
 
What Does ERP Do?
The real power of Epicor ERP software lies in its ability to simplify complexity. Here’s how it works:

• Centralises Business Data – One source of truth for all your operations.
• Automates Workflows – Reduce manual tasks and human error.
• Enables Collaboration – Break down silos so teams can work together seamlessly.
• Tracks Performance – Real-time analytics and dashboards to monitor KPIs.

 
Whether you’re a small business looking to scale or a mid-sized enterprise optimising processes, Epicor ERP creates the foundation for sustainable growth.
 
Key Benefits of Epicor ERP Software:
Still wondering if ERP is right for your business? Here are the top benefits companies experience:

• Improved Productivity – Streamlined workflows free up your team to focus on high-value tasks.
• Cost Savings – Better resource allocation and reduced duplication lower operational expenses.
• Better Customer Service – With accurate, up-to-date information, your team can respond faster and more effectively.
• Scalability – Cloud ERP solutions grow with your business, adapting to your needs over time.

 
Why Choose Blue Sky ERP?
At Blue Sky ERP, we specialise in helping small and mid-sized businesses unlock the full potential of the Epicor Kinetic ERP cloud-based platform.
 
Our solution includes modules for:

• Finance & Accounting
• Customer Relationship Management (CRM)
• Supply Chain & Inventory
• Order Processing
• Production Management
• Business Intelligence & Reporting

 
With Blue Sky ERP, you get the tools to optimise operations, reduce costs, and improve customer satisfaction - all while preparing your business for future growth.
 
Frequently Asked Questions (FAQs)
 
1.What does ERP stand for?
ERP stands for Enterprise Resource Planning, a type of software that integrates key business processes into a single system.
 
2.Who needs ERP software?
ERP isn’t just for large enterprises - small and mid-sized businesses can benefit significantly by improving efficiency, visibility, and scalability.
 
3. How is cloud ERP different from on-premise ERP?

• Cloud ERP is hosted on the internet (like Blue Sky’s Kinetic Epicor ERP solution), making it accessible anywhere, with lower upfront costs and automatic updates.
• On-premise ERP is installed locally on company servers, some businesses may prefer an on-premise solution for specific reasons.

 
4. How long does it take to implement ERP software?
Implementation depends on business size, complexity, and requirements. Some small businesses can go live in a few weeks, while larger projects may take several months.
 
5. What are the biggest benefits of Epicor ERP for small businesses?

• Centralised data
• Reduced manual errors
• Increased productivity
• Better financial control
• Flexibility to scale as you grow

 
6. Is ERP software expensive?
Costs vary, but cloud-based Epicor Kinetic ERP from Blue Sky ERP is typically more affordable with subscription-based pricing, making it accessible to growing businesses without heavy upfront investment.
 
7. Can ERP integrate with other tools we already use?
Yes. Modern ERP systems are designed with integration in mind, so they can connect with CRM tools, eCommerce platforms, banking systems, and more.
 
Take control of your business operations. Contact Blue Sky ERP today - streamline your business operations and scale effectively.

​

​Epicor customers will often think that by implementing advanced planning and scheduling within their organisation that all the heartache and woes of a real life production environment will be resolved.
 
The reality of advanced planning and scheduling (APS) is that it will seldom satisfy these high expectations on your first attempt. This is not necessarily down to the incorrect operation of the software but can often be down to the misunderstandings of your own organisation. As the old IT proverb goes, garbage in garbage out (GIGO).

​What is highly common within manufacturing businesses is an over optimism when looking at the times required to complete manufacturing processes, within the world of Epicor we refer to these processes as operations. If you were look at your own business and find 3 operators whom perform the same semi-skilled task, I'm sure if you asked each of them how long the task would take to complete you may arrive at a minimum of 2 different answers. So which time do you choose to be your operational estimate? To start with using an average would be the sensible option provided the times given are considered realistically achievable. You will usually find the more skill driven the operation the harder it will be to estimate the time required; with less skill and / or more automation operation times will inherently be more accurate.
 
When modelling your real life processes within Epicor for each of your products or services you will need to define a method of manufacture (MOM). The MOM can consist of both materials (BOM) and operations (BOO). The MOM can be engineered to order and created within the quote, pre-engineered through the engineering work bench or created within the job on the fly. Before you can schedule production an Epicor job must be created which will hold all details of the MOM. The diagram below shows a typically example of an Epicor MOM.

​The most important thing to remember when creating your MOM is that you want it to best represent your standard practices and for at least in the early days ignore what small exceptions might occur. Every business can be very different in terms of their processes but Epicor can offer a multiplicity of options when creating the MOM. The following describes not all but some of the functionality available in APS for Epicor ERP.

​Bill of Materials – The BOM defines what materials are required to complete a product or process. The quantity of material can be set to be proportional to the quantity of goods being produced or they can be set to a fixed quantity regardless of the production quantity. The BOM can consist of purchased and manufactured materials; manufactured materials can be set to pull from stock or to be made part of the job contained within sub-assemblies. Sub-assemblies can also be setup as phantom boms where on job creation the sub assembly explodes and part materials relocate to the next assembly level. Each material can be associated with specific operations contained within the BOO. In scheduled jobs which can span several days or weeks, this will dictate the time and date in which the material is required.
 
Bill of Operations - When setting up the BOO multiple operations can be stringed together in a sequence and dependencies can be added by the use of sub-assemblies which in turn can contain further sequences of operations and further sub-assemblies. Against each operation a time element is specified, the time the operation takes to complete can be proportional to job quantity or can be fixed.
 
Scheduling Relationships – Dependencies of operations can be further refined by the use of the scheduling relationship. A string of operations are commonly set to start when the previous operation has finished, within Epicor you also have the ability to schedule a sequence of operations to start or finish together. If using start to start scheduling further refinement can be made by using the send ahead offset where by you can set what quantity or percentage of operations to be completed before the next operation can be started. The following diagram below shows operations over time with the various scheduling relationships available.

​Resources - Within Epicor both people and machines can be considered a resource; a group of people or machines which can complete the same tasks are collected together in resource groups. Resource groups or individual resources are appended to operations as scheduling requirements. Essentially anything that can be considered as a constraint (aside from materials) can be setup and considered a resource scheduling requirement. For example a manufacturing plant may have several machines but not all machines can be run simultaneously, not because of a limitation on available operators but because of a limitation on the available power to the premises, therefore against this type of operation we could append the machine, the operator and the power consumed as scheduled resource requirements.
 
Resource Capacity - When setting up resources we have the ability within Epicor to define its capacity typically by the calendar, specifying the number of operational hours in a day and working days in a week in which the resource is available. Consider however that a machine can be available 24/7 but unless you always have an operator to run it you will always be bound by the operator as being one of your primary constraints. Additionally we can specify a daily or concurrent capacity whereby the unit of measure is anything you want it to be. An example of a daily capacity could be where a machine could not exceed a stated level of emissions in a single day. In the example of required power being a scheduled resource, this would suit a setting of a concurrent capacity in kW’s; this would allow multiple operations to be scheduled against a single resource until the stated concurrent capacity is reached but not exceeded.
 
Finite or Infinite Capacity - Although capacity for a resource will be defined you are not necessarily fixed by this constraint when running APS as you can still set resources to have an infinite or finite capacity. If setting a resource to be infinitely scheduled then there is potential for the scheduled load to exceed the available time. There is nothing wrong with running your scheduling this way as you still have the ability to measure by how much your available resource capacity has been exceeded by the demand for which you can act accordingly. Conversely if your resource is finite then the APS scheduler will never exceed the capacity, again there is nothing wrong with this method but I would advise against it in the early days of running APS until such time you have passed through the GIGO phase. After this phase you would typically end up with a mixture of infinite and finite resources where the bottle necks in your production would generally be set to finite.
 
Queue and Move Times – As products move through production it is unlikely new operations are started as soon the previous operation dictates. There can often be a time lag within your production where materials may take time to be moved to another location in the factory or a small element of time is required as a buffer. Within Epicor we can set queue times on the start of operations or move times on the end of operations. This time element does not consume any resource capacity but are used to create gaps between scheduled operations which are considered a realistic reflection of your production.
 
Setup Times - Time can be added to the start of an operation for which the length of time required for setup is not bound by total quantity of parts being produced, however setup times are not necessarily fixed as they can also be variable by the use of scheduling blocks to define the number of resources which can be utilised during a single operation.

​Scheduling Blocks - Imagine you have 3 machines which can complete the same operation, against the scheduled resource group I can set a scheduling block value of 3 meaning that I can run the operation on up to 3 machines simultaneously and thus reducing the process time to 1/3 of its original. When the APS schedules this operation it will firstly look for available capacity on 3 machines, if this capacity is not available it will look to schedule the operation against 1 or 2 machines depending on the availability of machine resources. The following diagram shows how process times can be reduced by the use of scheduling blocks.

​It is only advisable to use scheduling blocks if this is typical of your production environment; also bear in mind that if scheduling operations against 3 machines then you may require 3 individual setups increasing the accumulative process time and potentially the cost.
 

​Constrained Materials – A key constraint to scheduling can be materials, after all what is the point in scheduling without knowing the availability of materials. Within Epicor not all materials have to be considered as constraints, instead Epicor allows you to choose which materials should be treated as constrained. What one business may consider to be constrained material can be different in another; Typically constrained materials may be purchased parts on long lead times or they maybe materials which a business chooses not to stock due to their infrequent use. Constrained materials can be both purchased and manufactured parts. When planning with constrained materials the APS scheduler will not consider to start an operation until all related materials can be expected to be available. This means that again scheduling can be influenced by the GIGO effect. Your production planning has the potential to be largely influenced by your Purchasing department. Without good management of open purchases and regular maintenance of purchase lead times the use of constrained materials when planning via APS can be a non-starter.
 
Global Scheduling - Within APS global scheduling can be used to automatically reschedule Epicor jobs to suit the changes in your manufacturing environment. The global scheduler will consider both the availability of materials and the scheduled resources. The global scheduler will stick within the rules of the parameters you have set and will not exceed resource capacities or ignore material constraints assuming you have chosen them. The Global scheduler is not a magic box, it simply follows a logic and schedules jobs in order of their priority while sticking within the rules you have defined. What is more important than the use of the Global scheduler is understanding the calculation of scheduled priority; this is handled by the Calculate Scheduling Order Process.
 
Calculate Scheduling Order – To calculate the order of scheduled priority, firstly all jobs are hypothetically scheduled forward with an immediate start date based on an infinite availability resources but still sticking within the resource calendars and material constraints. This returns a theoretical optimum date to which a job can be completed; this date maybe before or after the job required due date. From this a days late value can be calculated, jobs hypothetically scheduled before the required due date would have a negative days late value. Once all jobs are scheduled the job with the lowest value of days late would be used to calculate a correction value. If the earliest job is 35 days earlier than it required due date then the correction value would be 36 (35 + 1). The graph below shows jobs A to E where the days late value has been calculated, job C has the lowest day’s late value of -35.

The correction value is added to the calculated days late of each job to give a shifted day’s late value and this is in turn multiplied by a priority factor to give the weighted priority value. The priority factor is taken from priority code stored against the job. There are six priority codes setup within a standard system but they can be amended to be business specific, the higher the priority factor number the more likely the job will be at the front of the global schedule queue.
​
The job with the highest weighted priority will have a scheduled sequence of 10, the second highest will have a scheduled sequence of 20 and so on and so forth; the higher the weighted priority then the lower value of scheduled order it will have. The following table shows Jobs A to E whereby the shifted days late, weighted priority and scheduling order has been calculated. 

Notice that although Job D has the highest days late value it is not the first in the scheduled order due to Job A having a greater priority factor.
​
Manual Scheduling – When using APS it is not mandatory to use Global scheduling, for Production environments with a relatively small number of jobs you can choose to manually schedule all jobs and still stick within your defined rules of available capacity and materials. For larger production facilities there will always some element of manual scheduling combined with Global scheduling.
What If Scheduling – When scheduling jobs either manually or globally you have the ability to schedule in an off-line mode where your real schedule is not affected until you choose too. This can be particularly useful when trying out different scheduling scenarios. What if schedules can also be saved and reloaded as and when required.
Job Scheduling Board – The Job scheduling board gives the planner the ability to view production in a gantt chart format. Whole jobs are displayed and can be manually re-planned by dragging and dropping jobs to different locations on the chart. The chart is colour coded to show where jobs maybe on time, late or part completed. All planning within the Job scheduling board is in What if mode until you decide to commit the schedule.

​Multi Resource Scheduling Board – The multi resource scheduling board is very similar in appearance to the job scheduling board but displays only planned operations against a selection of chosen resources. Operations can be re-planned by dragging and dropping individual operations, before the operation is rescheduled you have multiple options to schedule the operation only, the entire job or any proceeding operations.

​Resource Load Graph – The resource group load graph can be used to quickly see a picture of load against individual resources or resource groups overall. The graph will plot capacity, current load and what if load. 

There are a multiple of other tools and options available within the Epicor APS module, once you have mastered them and can accurately model your production environment the hard work still needs to continue. An ongoing maintenance is required for all system data including the managing of open jobs with timely and accurate completions, open purchases and part lead times, and the changes to your available resources with considerations to down time and maintenance.
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If your company is interested in Epicor APS or other Epicor ERP solutions please get in contact via the details below and unlock the potential in Epicor ERP.