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SZP ERPdemo for SZP PLAST Sp. z o.o., fictitious data

A working ERP demo for injection moulding at SZP PLAST: RFQ, costing, quotation, order, machine plan, production, quality, warehouse and shipping in one flow. Synthetic data, for learning and decision-making.

What this demo is

SZP ERP is a working model of an ERP system for a plastics injection moulding plant: one system handles a case from the customer RFQ through costing, quotation, order, machine plan, production and quality to shipping with documents. It is for learning and for deciding whether and how to build the full system.

All data is fictitious: companies, people, part numbers and prices. The demo does not connect to Comarch or any company system and does not send e-mails to customers.

Process and decision gates

Request for quotation (RFQ). The sales rep registers parts with volume, resin, weight, cavities and cycle. The process engineer reviews feasibility; without the review there is no quotation.
Costing. QF2 sheet method: material with runner, machine time and labour from cycle, cavities and OEE, changeover per batch, secondary operations, packaging, scrap, SGA and margin on price.
Quotation. A margin below the threshold requires director approval. The quotation has versions and a print in the customer's language.
Customer decision. An accepted quotation creates parts (development), moulds (in build), routing and bill of materials. A rejected one records the reason.
PPAP. Without approved PPAP a series work order cannot be released (only a trial one).
Order and requirements. An order with a delivery schedule; requirements show lines not covered by stock or production.
Machine plan. A work order goes to a compatible injection machine (the preferred one if it meets the due date); the schedule follows the 3-shift and holiday calendar, with changeover and buffer. Release checks PPAP, mould and material.
Production. Start, first-off (quality), shift reports: FIFO material consumption, part lot with genealogy, mould counter, OEE.
Quality. Lots wait for inspection; a blocked lot goes to quarantine with a nonconformity (8D). Closing requires a root cause and an action.
Shipping. Picking from released lots only, oldest first; delivery note, packing list in the customer's language, barcode labels.

Roles

No.	Role	What it records
1	Administrator	Everything, including accounts, settings, simulation and demo data reset.
2	Director	Approves quotations with margin below the threshold, runs shift simulation.
3	Sales rep	Customers, RFQs, costings, quotations, customer orders, shipments.
4	Process engineer	Parts, moulds, machines, routings and bills of materials, feasibility review.
5	Planner	Production requirements, work orders, machine plan, material orders, shift simulation.
6	Buyer	Suppliers, materials, purchase orders and receipts.
7	Production supervisor	Starting work orders and shift reports on the shop floor.
8	Quality	First-off approval, releasing and blocking lots, nonconformities, PPAP.
9	Warehouse clerk	Receipts, adjustments, picking and shipping.
10	Observer	View only (management, training).

Every logged-in user sees the whole system; write rights are split as in the plant. The administrator can view the system as a chosen role (Role view in the header).

Plant clock and simulation

The plan, due dates and KPIs are calculated from the plant clock. Usually it is real time. The “Simulate shift” button on the dashboard runs one shift through the whole plant (deliveries, planning, production, quality, shipments) and moves the clock to its end; the header then shows “simulation”. Actions are performed by fictitious people from each department.

Glossary

RFQ: Customer request for quotation.
SOP / EOP: Start and end of series production of the part at the customer.
MOQ: Minimum order quantity; here: the batch from costing rounded up to full packs.
SGA: General, selling and administrative costs added to the manufacturing cost.
PPAP: Production Part Approval Process, an automotive customer requirement before series production.
OEE: Overall equipment effectiveness: availability (run time / planned time) x performance (standard cycle time / run time) x quality (good / all).
MRP: Requirements planning: demand from orders minus stock and work in progress gives the work orders to create; the same for materials from the BOM.
BOM: Bill of materials of the part: resin per piece (with runner) and packaging.
FIFO: First in, first out: consumption and shipping from the oldest lot.
Lot: Traceability unit (lot) of material or part with a quality status: to inspect, released, blocked, scrapped.
Genealogy: The link between a part lot and the material lots it was made from; allows recalling only what is needed.
NCR / 8D: A nonconformity and the method to solve it: description, containment, root cause, corrective action, verification.
PZ, RW, PW, WZ, MM: Warehouse documents: goods receipt (PZ), issue to production (RW), receipt from production (PW), delivery to customer (WZ), transfer (MM).
FCA: Incoterms rule: the seller hands the goods to the buyer's carrier at its own premises.

How it is built (scalability)

Modular monolith: each module (sales, master data, planning, production, quality, warehouse, shipping, purchasing) has its own PostgreSQL schema and its own logic. A module can grow and, if needed, be split into a separate service without rewriting the rest.
PostgreSQL with a connection pool; document numbering without table locks, warehouse writes with a lot row lock (two simultaneous issues cannot go below zero), each operation in a single transaction.
Stateless application server: more processes and servers can be added without code changes; sessions and data are in the database.
An audit log of every operation (who, when, what) and full lot traceability, as required by IATF 16949.

Demo simplifications and decisions before a full version

Comarch: in the full version invoices, accounting and KSeF stay in Comarch; the ERP passes delivery notes and receipts and takes master data. To decide: the scope and direction of data exchange.
The plan covers the moulding operation; metallization, painting and assembly add a fixed lead time. Full version: scheduling of the metallization chambers and paint line too.
Shift reports are entered by people. Full version: cycle counters and downtime directly from the machines (OPC UA, Euromap 77) and shop-floor terminals.
Customer orders entered manually. Full version: EDI (VDA 4905, DELFOR, DESADV) and shipment notices.
Labels in the browser. Full version: label printers and the customer label standard (Odette, VDA 4902, GTL).
Costs from costing. Full version: actual work order cost and variances to costing.
Outside the demo scope: maintenance of moulds and machines, SPC measurements, returnable packaging management, multiple plants.