IFS Modules

Overview of the Modules in IFS

This document gives a brief overview of the main

modules in IFS, including their key features and
how they support business operations. It helps
readers understand how IFS can improve efficiency
and decision-making across various functions.

Himanshi Jaiswal
Table of Contents

Finance Module......................................................................................3
Overview of the Finance Module in IFS ERP.............................................................3
Key Objectives......................................................................................................... 3
Main Sub-Modules / Components............................................................................3
Integration with Other IFS Modules.........................................................................5
Typical Transactions in IFS Finance.........................................................................5
Distribution Module................................................................................5
Overview of the Distribution Module in IFS ERP.......................................................5
Key Objectives......................................................................................................... 6
Main Sub-Modules / Components............................................................................6
Integration with Other IFS Modules.........................................................................8
Typical Transactions in IFS Distribution...................................................................8
Real-World Use Cases.............................................................................................. 8
Manufacturing Module............................................................................8
Overview of the Manufacturing Module in IFS ERP..................................................8
Key Objectives......................................................................................................... 9
Main Sub-Modules / Components............................................................................9
Integration with Other IFS Modules.......................................................................11
Key Benefits.......................................................................................................... 11
Typical Transactions in IFS Manufacturing............................................................11
Supported Manufacturing Types........................................................................12
Example Business Flow......................................................................................... 12
HRMS Module.......................................................................................12
Overview of HRMS Module in IFS ERP....................................................................12
Key Objectives....................................................................................................... 13
Main Submodules / Components...........................................................................13
Integration with Other IFS Modules.......................................................................15
Key Benefits.......................................................................................................... 15
Typical Transactions in IFS HRMS..........................................................................15
Example Business Flow......................................................................................... 16

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Enterprise Asset Management (EAM) Modules........................................16
Overview of the EAM Module in IFS ERP................................................................16
Key Objectives....................................................................................................... 16
Main Submodules / Components...........................................................................17
Integration with Other IFS Modules.......................................................................18
Key Benefits.......................................................................................................... 19
Typical Transactions in IFS EAM............................................................................19
Example Business Flow......................................................................................... 20
Industry Use Examples.......................................................................................... 20
Process Manufacturing Module.............................................................20
Overview of the Process Manufacturing Module in IFS ERP...................................20
Key Objectives....................................................................................................... 20
Main Submodules / Components...........................................................................20
Integration with Other IFS Modules.......................................................................23
Key Benefits.......................................................................................................... 23
Typical Transactions in IFS Process Manufacturing...............................................23
Example Business Flow......................................................................................... 24
Industries Benefiting from IFS Process Manufacturing..........................................24

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Finance Module

Overview of the Finance Module in IFS ERP

The Finance module in IFS Cloud / IFS Applications is a core component of the ERP
system that manages an organization’s financial transactions, reporting,
compliance, and performance management. It provides a complete, integrated
financial management solution — from basic accounting to advanced corporate
finance and analytics — ensuring data accuracy, transparency, and control.

Key Objectives
 Centralize all financial data and processes across business units.
 Support statutory and management accounting requirements.
 Enable real-time financial reporting and decision-making.
 Maintain compliance with international accounting standards (IFRS, GAAP, etc.).
 Integrate financials with operations such as Procurement, Inventory, Projects,
and HR.

Main Sub-Modules / Components

[Link] Ledger (GL)

 Acts as the financial backbone of the system.

 Records all financial transactions through automatic postings from sub-ledgers.
 Supports multiple reporting currencies, periods, and fiscal calendars.
 Provides financial statements such as Balance Sheet, P&L, and Trial Balance.
Key Features:
 Multi-company and multi-currency support
 Journal entry management and approvals
 Period closing and consolidation
 Real-time integration with other modules

2. Accounts Payable (AP)

 Manages vendor invoices, payments, and supplier reconciliations.

 Integrates with Procurement and Inventory for 3-way matching (PO, GRN,
Invoice).
Key Features:
 Invoice registration and matching
 Payment scheduling and processing
 Supplier aging and analysis reports
 Tax handling and compliance

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3. Accounts Receivable (AR)

 Manages customer invoices, receipts, and credit control.

 Integrates with Sales and Projects for automated billing.
Key Features:
 Customer invoicing (manual and automatic)
 Payment collection and allocation
 Credit limit and dunning management
 Customer statement and aging reports

4. Cash & Bank Management

Manages all bank accounts, transactions, and cash flows.

Key Features:
 Bank reconciliation (manual and automatic)
 Cash forecasting and liquidity planning
 Electronic payments and receipts
 Integration with AP, AR, and GL

5. Fixed Assets Management

Handles the full life cycle of assets — acquisition, depreciation, transfer, and
disposal.
Key Features:
 Asset registration and classification
 Multiple depreciation methods
 Asset revaluation and impairment
 Integration with Projects and Procurement

6. Budgeting and Forecasting

 Provides tools to plan, control, and monitor budgets.

 Integrates with GL for variance analysis and reporting.
Key Features:
 Budget creation and versioning
 Forecast adjustments
 Budget vs. Actual comparison
 Scenario and what-if analysis

7. Cost Accounting & Controlling

Tracks and allocates costs to cost centers, projects, or products.

Key Features:
 Cost element and cost center hierarchy
 Internal cost allocations
 Profitability and variance analysis

8. Consolidation & Financial Reporting

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Consolidates results from multiple entities and supports group reporting.
Key Features:
 Multi-company, multi-currency consolidation
 Intercompany eliminations
 Statutory and management reporting
 Real-time dashboards and analytics

Integration with Other IFS Modules

The Finance module is fully integrated with:

Procurement – Supplier invoices and payments
Sales – Customer billing and receipts
Projects – Project cost control and revenue recognition
Inventory – Material valuation and costing
HR & Payroll – Payroll postings to GL

Typical Transactions in IFS Finance

Journal Entries, Period Closing,
GL
Adjustments
Supplier Invoice Entry, Payment Run, Invoice
AP
Matching
AR Customer Invoice, Receipt Entry, Credit Memo
Bank Bank Statement Upload, Reconciliation
FA Asset Acquisition, Depreciation Run, Disposal
Budget Budget Entry, Revision, Comparison
Consolidation Intercompany Elimination, Group Reporting

Distribution Module

Overview of the Distribution Module in IFS ERP

The Distribution module in IFS ERP (IFS Cloud / IFS Applications) manages all
aspects of a company’s supply chain and logistics operations, from procurement to
sales and delivery. It ensures smooth movement of materials, goods, and
information across the supply chain — connecting suppliers, warehouses, and
customers within a single integrated system.
It supports businesses in planning, executing, and controlling the entire distribution
cycle efficiently — improving inventory visibility, customer service, and cost control.

Key Objectives
 Streamline procurement, inventory, and order management processes.
 Optimize stock levels and material flow.
 Improve order fulfillment accuracy and delivery timelines.

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 Enable full traceability of goods and materials.
 Integrate supply chain operations with financials and manufacturing.

Main Sub-Modules / Components

1) Procurement / Purchasing

Handles all purchasing activities — from requisition to payment — ensuring the right
goods are ordered from the right suppliers at the right price.
Key Features:
 Purchase requisition and approval workflow
 Request for Quotation (RFQ) and supplier response management
 Purchase order creation and release
 Goods receipt and inspection
 Supplier evaluation and performance tracking
 Integration with Accounts Payable for invoice matching

2) Inventory Management

Manages inventory across multiple warehouses, ensuring accurate stock tracking,

valuation, and replenishment.
Key Features:
 Real-time stock visibility and valuation
 Lot and serial number tracking
 Stock movements, transfers, and adjustments
 Cycle counting and physical inventory
 ABC analysis and safety stock planning
 Integration with Manufacturing and Sales modules

3) Sales & Order Management

Handles the entire sales order process — from order entry to delivery and invoicing
— ensuring efficient customer service and fulfillment.
Key Features:
 Customer quotation and order creation
 Pricing, discounts, and promotions
 Availability checking and ATP (Available-to-Promise)
 Order picking, packing, and shipping
 Return material authorization (RMA) handling
 Integration with AR and CRM

4) Customer Relationship Management (CRM)

Supports customer interactions and service management linked to sales and

distribution activities.
Key Features:

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 Customer master data and history
 Quotation and opportunity management
 Contract management and renewals
 Customer communication and service follow-up

5) Warehouse Management

Provides control and optimization of warehouse operations — including put-away,

picking, and shipping.
Key Features:
 Warehouse structure and bin management
 Barcode and RFID integration
 Picking strategies (FIFO, LIFO, batch)
 Cross-docking and wave picking
 Shipment planning and tracking
 Integration with logistics and transport planning

6) Transportation & Logistics

Manages outbound and inbound logistics, shipment planning, and freight cost
control
Key Features:
 Carrier and route management
 Shipment scheduling and consolidation
 Freight calculation and documentation
 Delivery note and bill of lading generation
 Integration with 3PL and freight forwarders

7) Demand Planning & Forecasting

Supports planning of inventory replenishment based on sales history, seasonality,

and forecast models.
Key Features:
 Statistical demand forecasting
 Sales history analysis
 Reorder point and replenishment suggestions
 Integration with Inventory and Sales

8) Returns & After-Sales Service

Handles product returns, replacements, and service logistics.

Key Features:
 Return Material Authorization (RMA)
 Warranty and service agreement tracking
 Repair and replacement management
 Integration with CRM and Finance

Integration with Other IFS Modules

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Integrated
Integration Purpose
Module
Finance (AP, AR,
Purchase and sales invoicing, inventory valuation
GL)
Manufacturing Raw material supply and finished goods dispatch
Project-specific material procurement and
Projects
delivery
Maintenance Spare parts and service materials
HR Approval workflows for requisitions and orders

Typical Transactions in IFS Distribution

Submodule Common Transactions

Procurement Create Purchase Requisition, RFQ, PO Creation, Receipt
Inventory Stock Move, Transfer Order, Cycle Count, Adjustment
Sales Create Quotation, Sales Order Entry, Delivery, Invoice
Warehouse Pick List, Ship Confirm, Packing, Dispatch
Logistics Shipment Planning, Carrier Assignment, Freight Costing
Returns RMA Entry, Receipt of Returned Goods, Replacement

Real-World Use Cases

 Manufacturing companies: Manage raw material procurement and finished

goods distribution.
 Retail & Wholesale: Control multi-location inventory and optimize order
fulfillment.
 Project-based firms: Handle project-specific materials and logistics.
 Service providers: Manage spares, returns, and warranty replacements.

Manufacturing Module

Overview of the Manufacturing Module in IFS ERP

The Manufacturing module in IFS ERP (IFS Cloud / IFS Applications) is designed to
manage the end-to-end production lifecycle — from planning and scheduling to
execution, costing, and analysis.
It provides a comprehensive and flexible solution that supports different
manufacturing types such as Make-to-Stock (MTS), Make-to-Order (MTO), Engineer-
to-Order (ETO), and Project-Based Manufacturing.
The goal is to ensure efficient production planning, resource utilization, and on-time
delivery of quality products while maintaining cost control and traceability.

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Key Objectives

 Optimize manufacturing operations and production efficiency.

 Balance demand, capacity, and inventory through advanced planning.
 Improve visibility across the entire production process.
 Support multiple manufacturing environments and product structures.
 Provide accurate product costing and performance analysis.

Main Sub-Modules / Components

1. Product Structures (BOM & Routing Management)

Defines how products are built and the sequence of operations required.
Key Features:
 Bill of Materials (BOM) creation and version control
 Routing definition and operation sequencing
 Alternate BOMs and routings
 Engineering change control (ECOs)
 Integration with Product Data Management (PDM) and Engineering

2. Manufacturing Planning (MRP / MPS)

Supports planning of materials, capacity, and resources based on demand forecasts

and production orders.
Key Features:
 MRP (Material Requirements Planning) – ensures material availability
 MPS (Master Production Schedule) – plans long-term production
 Capacity requirements planning
 Forecast-based and demand-driven planning
 Rescheduling and exception messages

3. Shop Order Management (Production Execution)

Manages the execution of production orders from release to completion.

Key Features:
 Creation, release, and tracking of shop orders
 Material issue and backflush
 Operation reporting and labor time recording
 Partial and final completion reporting
 Quality inspection and approvals
 Integration with Inventory for material consumption and output

4. Capacity & Resource Planning

Optimizes utilization of machines, labor, and work centers.

Key Features:
 Work center and resource definition
 Load balancing and finite/infinite capacity scheduling

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 Resource calendar management
 Real-time monitoring of capacity utilization

5. Manufacturing Costing

Provides tools to track and analyze manufacturing costs throughout the production
cycle.
Key Features:
 Standard and actual cost calculation
 Cost roll-up from BOM and routing
 Variance analysis (material, labor, overhead)
 Integration with GL for financial posting
 Product profitability analysis

6. Shop Floor Reporting & Control

Allows operators and supervisors to monitor and record real-time shop floor
activities.
Key Features:
 Operation status updates (Start, Pause, Stop, Complete)
 Labor and machine time entry
 Work order tracking and performance KPIs
 Integration with IoT and MES systems

7. Engineering and Configuration Management

Handles configurable and engineered products through rules-based product design.

Key Features:
 Product configuration models (for custom orders)
 Engineering change management (ECN/ECO)
 Revision control for designs and routings
 Integration with CAD/PDM systems

8. Quality Management

Ensures production quality and compliance throughout the process.

Key Features:
 In-process and final inspections
 Non-conformance reporting (NCR)
 Corrective and preventive actions (CAPA)
 Integration with Production, Purchasing, and Inventory

9. Manufacturing Scheduling & Execution (Advanced Planning)

Supports dynamic scheduling for optimized production sequences.

Key Features:
 Finite capacity scheduling
 Gantt chart visualization of operations

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 Prioritization and rescheduling tools
 Integration with work orders and capacity planning

Integration with Other IFS Modules

Integrated
Purpose
Module
Inventory Material availability, consumption, and output tracking
Procurement Purchase of raw materials and subcontracting
Finance Posting of manufacturing costs, WIP, and variance
Projects Project-based manufacturing and cost tracking
HR Labor tracking and resource allocation
Maintenance Equipment maintenance and downtime management
Sales & Distribution Order-driven manufacturing and delivery planning

Key Benefits
 Improved production efficiency and reduced lead times
 Accurate material and capacity planning
 Real-time visibility into production status
 Lower manufacturing costs through waste reduction
 Better coordination between engineering, production, and finance
 Enhanced product quality and compliance control

Typical Transactions in IFS Manufacturing

Submodule Common Transactions

Product
Create BOM, Define Routing, Engineering Change
Structure

Planning Run MRP/MPS, Review Exceptions, Generate Shop Orders

Release Shop Order, Issue Material, Report Operation, Close
Production
Order
Costing Update Standard Cost, Analyze Variance, Post to GL
Quality Create NCR, Perform Inspection, Approve Product
Resource Define Work Center, Schedule Operation, Track Utilization

Supported Manufacturing Types

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Manufacturin Typical IFS ERP
Description
g Type Industry Capabilities
Produces individual,
Automotive, BOMs, Routings,
Discrete countable items assembled
Electronics Shop Orders
from parts
Produces goods in batches or Recipe
Food, Chemicals,
Process continuous flow; cannot Management, Lot
Pharma
disassemble Control
Custom design and Heavy
Project Integration,
ETO production per customer Equipment,
Design Control
order Construction
Product
Product configured from Electronics,
CTO Configurator,
predefined options Furniture
Dynamic BOM
Repetitive / High-volume, standardized FMCG, Plastics, Line Scheduling,
Batch production Packaging Backflushing

Example Business Flow

1. Sales Order / Forecast triggers MRP → generates planned shop orders.

2. Planner reviews and releases shop orders.
3. Materials are issued from inventory → production begins.
4. Operators report progress and completions on the shop floor.
5. Finished goods are received into inventory and costed.
6. Variances are analyzed and posted to Finance.

HRMS Module

Overview of HRMS Module in IFS ERP

The HRMS module in IFS ERP (IFS Cloud / IFS Applications) provides a
comprehensive, integrated solution for managing the entire employee lifecycle —
from recruitment and onboarding to payroll, performance, and offboarding.
It helps organizations streamline HR processes, ensure regulatory compliance, and
empower employees and managers through self-service functionalities.
The HRMS module is often integrated with Payroll, Finance, Projects, and Time &
Attendance, giving HR professionals and management a unified view of workforce
data.

Key Objectives
 Centralize all employee-related information and HR processes.
 Automate recruitment, onboarding, and workforce administration.
 Support performance, development, and retention initiatives.
 Ensure compliance with labor laws and company policies.
 Provide analytics for workforce planning and decision-making.

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Main Submodules / Components

1. Core HR / Personnel Administration

This is the foundation of the HRMS module, managing employee master data and
employment details.
Key Features:
 Employee master data (personal, employment, and organizational details)
 Position and job structure management
 Employment types, grades, and hierarchies
 Document and record management
 Organization structure and reporting relationships
 Integration with Finance for cost center assignments

2. Recruitment & Onboarding

Manages the entire hiring cycle from vacancy creation to employee onboarding.
Key Features:
 Job requisition and approval workflows
 Candidate application tracking (ATS)
 Interview scheduling and evaluation
 Offer management and hiring decisions
 Onboarding checklist and induction management
 Integration with Core HR for employee creation

3. Time & Attendance (T&A)

Tracks employee working hours, attendance, shifts, and leave management.

Key Features:
 Work schedule and shift definitions
 Attendance tracking and overtime calculation
 Leave requests and approvals
 Integration with Payroll for pay calculations
 Support for biometric and timesheet-based recording

4. Leave Management

Manages leave types, accruals, and approvals for employees.

Key Features:
 Leave policy setup (annual, sick, casual, etc.)
 Automatic accrual and carry-forward rules
 Leave request workflows and approvals
 Integration with calendars and attendance

5. Payroll Management (if implemented)

Handles salary calculation, deductions, and statutory compliance.

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Key Features:
 Payroll setup and salary structure configuration
 Earnings, deductions, and tax calculations
 Integration with Time & Attendance and Finance (GL postings)
 Pay slip generation and payroll reports
 Statutory compliance (PF, ESI, Income Tax, etc.)

6. Performance Management

Monitors and evaluates employee performance to support appraisals and

development.
Key Features:
 Goal setting and KPI assignment
 Mid-year and annual appraisal processes
 360° feedback and performance ratings
 Performance-linked incentives or increments
 Integration with Learning & Development

7. Learning & Development (L&D)

Supports training and skill development programs.

Key Features:
 Training needs analysis
 Course scheduling and nomination management
 Attendance tracking and feedback
 Skill and competency mapping
 Integration with Performance Management
8. Compensation & Benefits

Manages salary structures, increments, and employee benefits.

Key Features:
 Compensation review and approval workflows
 Benefits eligibility and enrollment
 Bonus and incentive management
 Integration with Payroll and Finance

9. Employee Self-Service (ESS) & Manager Self-Service (MSS)

Empowers employees and managers to perform HR activities independently.

Key Features:
 Employees can update personal details, apply for leave, view payslips.
 Managers can approve leave, view team information, initiate requests.
 Reduces administrative burden on HR.

[Link] / Offboarding

Handles exit processes and ensures compliance with exit policies.

Key Features:
 Resignation and exit approval workflows
 Clearance and handover process

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 Final settlement and document issuance
 Exit interview management

Integration with Other IFS Modules

Integrated Module Purpose

Finance Payroll posting, cost center accounting
Projects Resource allocation and project costing
Time & Attendance /
Working hours and overtime integration
OTL
Procurement / Access and asset assignment for
Inventory employees
Security /
Role-based access and HR data security
Authorization

Key Benefits
 Centralized HR data management
 Improved transparency and compliance
 Enhanced employee engagement through self-service
 Time savings through automation and integration
 Real-time HR analytics and reporting
 Better workforce planning and decision-making

Typical Transactions in IFS HRMS

Submodule Common Transactions

Employee Creation, Position Assignment, Record

Core HR
Update

Recruitment Vacancy Creation, Interview Evaluation, Offer Issue

Time & Shift Entry, Attendance Update, Overtime

Attendance Calculation

Leave Leave Request, Approval, Balance Update

Payroll Payroll Run, Payslip Generation, GL Posting

Performance Goal Setting, Appraisal Entry, Rating Approval

Learning Training Schedule, Nomination, Feedback Entry

Separation Exit Initiation, Clearance, Final Settlement

Example Business Flow

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 Recruitment: HR raises requisition → Candidate selection → Onboarding.
 Core HR: Employee details maintained in master records.
 Time & Leave: Employee attendance and leaves recorded.
 Payroll: Salary processed and posted to GL.
 Performance: Periodic appraisals and training conducted.
 Separation: Offboarding, clearance, and full settlement handled.

Enterprise Asset Management (EAM) Modules

Overview of the EAM Module in IFS ERP

The Enterprise Asset Management (EAM) module in IFS ERP (IFS Cloud / IFS
Applications) provides a complete and integrated solution for managing the entire
lifecycle of physical assets — from acquisition and operation to maintenance and
retirement.

It helps organizations maximize asset performance, reduce downtime, and optimize

maintenance costs while ensuring regulatory compliance and safety.

IFS EAM is widely used in industries like energy, utilities, manufacturing, aviation,
construction, oil & gas, and transportation, where asset reliability and availability
are business-critical.

Key Objectives
 Extend asset life and reliability through proactive maintenance.
 Optimize maintenance costs and resource utilization.
 Ensure regulatory compliance and safety standards.
 Provide real-time visibility into asset health and performance.
 Integrate maintenance activities with operations, projects, and finance.

Main Submodules / Components

1. Asset Register / Equipment Management

Central repository for all assets, including fixed, movable, and technical equipment.
Key Features:
 Asset master data (type, location, hierarchy, cost center)
 Asset classification and parent-child structures
 Warranty, supplier, and service contract details
 Asset history tracking (installation, transfers, usage)
 Integration with Fixed Assets and Inventory

2. Preventive Maintenance (PM)

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Plans and schedules regular maintenance activities to prevent breakdowns.
Key Features:
 Maintenance plan creation (time-based, usage-based, or condition-based)
 Automatic work order generation from schedules
 Maintenance calendar and frequency setup
 Integration with meters, sensors, and IoT for condition monitoring

3. Corrective Maintenance

Handles unplanned maintenance activities to repair or restore equipment after

failure.
Key Features:
 Work order creation from fault reports or operator feedback
 Priority assignment and downtime tracking
 Root cause analysis and failure coding
 Integration with Spare Parts Inventory and Purchasing

4. Work Order Management

Core function for managing all maintenance tasks — both planned and unplanned.
Key Features:
 Work request registration and approval
 Task planning (labor, materials, tools)
 Scheduling and assignment to technicians
 Work progress tracking and completion reporting
 Maintenance cost capture and analysis

5. Maintenance Planning & Scheduling

Optimizes allocation of maintenance resources, minimizing downtime and

disruptions.
Key Features:
 Maintenance planner board and Gantt chart view
 Resource availability and capacity analysis
 Workload balancing across technicians and shifts
 Integration with HR (for resource skills and availability)

6. Spare Parts & Inventory Integration

Ensures spare parts availability for timely maintenance execution.

Key Features:
 Integration with Inventory and Procurement modules
 Automatic material requisition and reservation
 Minimum and reorder level setup
 Cost tracking of parts used in maintenance

7. Work Execution & Mobile Maintenance

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Empowers maintenance teams with mobile tools for field operations.
Key Features:
 Mobile access to work orders, checklists, and asset data
 Offline capability for remote operations
 Photo/document upload and digital signatures
 Real-time updates to asset and maintenance records

8. Reliability & Condition Monitoring

Supports predictive maintenance by tracking asset condition data.

Key Features:
 Meter readings (runtime, pressure, temperature, etc.)
 Condition-based maintenance triggers
 Integration with IoT and SCADA systems
 Failure mode and effects analysis (FMEA)

10. Shutdown / Turnaround Management

Used in heavy industries to plan large-scale maintenance events.

Key Features:
 Project-based planning for shutdowns
 Work order bundling and sequencing
 Resource and material synchronization
 Post-shutdown review and reporting

Integration with Other IFS Modules

Integrated Module Purpose

Inventory Spare parts management, stock tracking

Purchase of maintenance materials and

Procurement
services

Cost accounting, capitalization, and

Finance (GL, FA)
depreciation

Projects Maintenance budgeting and cost tracking

HRMS Resource skill tracking, technician scheduling

Manufacturing Equipment maintenance for production lines

IoT / IFS IoT Business Condition monitoring and predictive

Connector maintenance

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Key Benefits
 Reduced unplanned downtime and breakdowns
 Lower maintenance and repair costs
 Enhanced asset reliability and utilization
 Better control over maintenance planning and resources
 Compliance with safety and regulatory requirements
 Real-time visibility into asset health and costs

Typical Transactions in IFS EAM

Submodule Common Transactions

Asset Register Create Asset, Transfer Asset, Update Asset Info

Preventive
Define Maintenance Plan, Generate Work Order
Maintenance

Corrective Maintenance Create Fault Report, Issue Work Order, Record Downtime

Work Order
Schedule Job, Assign Resources, Close Work Order
Management

Spare Parts Reserve Material, Issue from Inventory, Return to Stock

Record Labor Cost, Material Cost, Analyze Maintenance

Costing
Spend

Reporting Generate Asset Performance and Cost Reports

Example Business Flow

 Asset Creation: Asset details registered in Asset Register.
 Preventive Plan: Maintenance plan set based on usage or time.
 Work Order: Generated automatically or manually for maintenance.
 Execution: Technician performs maintenance, logs hours and materials.
 Completion: Work order closed, costs posted to GL.
 Analysis: Maintenance performance and cost reports reviewed.

Industry Use Examples

 Energy & Utilities: Power plant equipment, transformers, and turbines.
 Manufacturing: Production line machines and factory equipment.
 Oil & Gas: Pipelines, rigs, compressors, and valves.
 Aviation: Aircraft components, maintenance checks, ground equipment.
 Construction: Heavy machinery, cranes, and fleet assets.

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Process Manufacturing Module

Overview of the Process Manufacturing Module in IFS ERP

The Process Manufacturing module in IFS ERP (IFS Cloud / IFS Applications) is
specifically designed for industries where products are produced through formulas
or chemical processes rather than assembled from discrete parts.

It enables organizations to plan, produce, track, and control materials that are
mixed, blended, or processed in batches — ensuring quality, compliance, and cost
efficiency.

This module is commonly used in industries such as pharmaceuticals, food &

beverages, chemicals, paints, cosmetics, and oil refining.

Key Objectives
 Manage formulation- or recipe-based production efficiently.
 Ensure consistent product quality and compliance with regulations.
 Optimize material usage, yield, and batch sizing.
 Provide full traceability of ingredients and products.
 Integrate production with quality control, inventory, and costing.

Main Submodules / Components

1. Formula / Recipe Management

Defines the product composition, ingredients, and production instructions — similar

to a Bill of Materials in discrete manufacturing.
Key Features:
 Formula definition (ingredients, proportions, and output)
 Version control and formulation history
 Substitutes and alternate ingredients
 Unit of measure conversions and scaling
 Regulatory and labeling data management

2. Batch Management

Handles production in batches or lots, allowing flexibility in scaling and traceability.

Key Features:
 Batch creation and batch size control
 Yield tracking and adjustment
 Co-products and by-products management
 Batch genealogy (trace input → output)
 Batch rework and merging

3. Production Planning & Scheduling

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Plans and optimizes process orders based on demand, capacity, and material
availability.
Key Features:
 Batch scheduling (finite/infinite capacity)
 Tank and vessel capacity planning
 Material requirements planning (MRP) integration
 Sequencing to minimize cleaning/changeover time
 Integration with Inventory and Procurement

4. Shop Floor Execution

Manages the actual production process, ensuring accurate recording of material

consumption and output.
Key Features:
 Issue and return of ingredients (weighing, dispensing)
 Batch execution and status tracking
 Real-time data capture (temperature, time, operator inputs)
 Automatic material backflushing
 Integration with MES and IoT systems for process automation

5. Quality Management

Ensures that raw materials and finished goods meet defined standards throughout
the process.
Key Features:
 Quality inspection during production and release
 In-process and final QC testing
 Non-conformance and deviation management
 Lab sample tracking and results recording
 Integration with LIMS (Laboratory Information Management System)

6. Compliance & Traceability

Maintains full regulatory compliance and product traceability — critical for industries
like pharma and food.
Key Features:
 Batch genealogy (forward and backward traceability)
 Audit trails and electronic signatures (FDA 21 CFR Part 11 compliance)
 Material safety data sheet (MSDS) integration
 Shelf-life and expiry date management
 Allergen and hazardous material control

7. Costing & Yield Management

Provides tools for analyzing production costs and material yield variances.
Key Features:
 Standard, actual, and batch-level costing

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 Raw material, labor, and overhead cost tracking
 Scrap and rework costing
 Yield variance reporting and cost reconciliation
 Integration with General Ledger for automatic postings

8. Inventory & Material Management

Ensures proper handling of raw materials, intermediates, and finished goods within
process production.
Key Features:
 Lot-controlled and expiry-based inventory management
 Material potency and concentration tracking
 Tank and container inventory control
 Warehouse integration and automated replenishment
 Integration with Procurement and Sales for supply chain visibility

9. Environmental, Health & Safety (EHS)

Supports safe operations and compliance with environmental and safety

regulations.
Key Features:
 Hazardous material tracking (HAZMAT)
 Safety data management and labeling
 Waste management and disposal tracking
 Environmental compliance reporting

Integration with Other IFS Modules

Integrated Module Purpose

Raw material, intermediate, and finished goods

Inventory
tracking

Procurement Purchase of raw materials and ingredients

Quality Management In-process and final quality control

Finance (GL, Costing) Cost accounting and variance analysis

EAM (Asset
Maintenance of production equipment and assets
Management)

Costing and control for process improvement or

Projects
plant setup

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Integrated Module Purpose

Supply Chain / Demand planning, warehouse, and logistics

Distribution integration

Key Benefits
 Improved batch consistency and product quality
 Full traceability and regulatory compliance
 Reduced material wastage and production cost
 Enhanced visibility across process operations
 Optimized utilization of equipment and resources
 Real-time production monitoring and control

Typical Transactions in IFS Process Manufacturing

Submodule Common Transactions

Formula
Create Recipe, Approve Formula, Update Version
Management

Batch Management Create Batch Order, Adjust Batch Size, Record Yield

Production
Issue Materials, Start/Stop Batch, Report Completion
Execution

Quality Control Record Test Results, Approve Batch, Handle Deviations

Record Actual Cost, Compare with Standard, Analyze

Costing
Variance

Inventory Reserve Materials, Transfer Lots, Manage Expiry

Example Business Flow

 Recipe Definition: Create and approve the product formula.
 Batch Planning: Plan batch orders based on demand and capacity.
 Production Execution: Issue raw materials → Mix/Process → Record output.
 Quality Testing: Inspect and release the batch after QC approval.
 Costing & Posting: Record costs and post production results to GL.
 Distribution: Transfer finished goods to warehouse for delivery.

Industries Benefiting from IFS Process Manufacturing

 Food & Beverages: Recipe management, shelf-life control, traceability.
 Pharmaceuticals: Batch records, FDA compliance, quality control.

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 Chemicals: Formulation management, hazardous material tracking.
 Paints & Coatings: Color formulation, viscosity and batch consistency.
 Cosmetics: Ingredient tracking, labeling, and regulatory reporting.

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