Manufacturing & Beyond

Streamline your business with our robust manufacturing system designed from the ground up for the bedding industry.


Manufacturing and Beyond is a complete manufacturing solution, designed by bedding manufacturers with today’s bedding industry in mind. It starts with a configuration tool that allows the designer to build a recipe (model) and then explode the bill of materials into separate inventory items for each bed size.

As customers request these items, the orders are added to a daily schedule which drives the production process. Bar-coded media is produced for each serialized piece to help track it through the operations on the manufacturing floor. Detailed information about the status of orders and individual items can be viewed at any time during the production process. On the manufacturing floor, a .NET-powered browser-based solution provides clear instructions to employees as they scan each piece through the production operations. This full-screen graphical interface also enforces FR lot number collection and includes pictures, multi-lingual prompts, and a running total of the day’s pay for piecework employees.

Completed pieces are bagged and scanned onto trucks using this same web interface, and employees can be paid piecework rates for these operations as well. Once a truck is loaded, the process comes full-circle back to the billing department as orders are finalized and paperwork generated for the entire load in one combined process.

Key Areas

Models

Create and explode models into different sizes, experiment with costs before comitting changes, and multi-level Bill of Materials support for reporting and global changes.

Scheduling

Schedule by order number, route and more, automatically create Loads and Delivery Schedules, and flexible last-minute order changes.

Manufacturing

Time-clock control, automatic piecework split pay, and integrated Lot Tracking.

Shipping

Create Loads on-the-fly, one-button bill of lading and invoice generation, and short shipments easily resolved to backorders, stock, or cancel.

Models

  • Design one model; Build-a-bed automatically explodes it to unlimited sizes.
  • Multi-level Bill of Materials with reports, global changes, etc.
  • Piecework labor can be integrated into cost calculations.
  • View and experiment with costs for all sizes before committing changes.
  • Each serial number created includes complete, costed bill of materials.
  • Changing models for future releases won’t disrupt production in-progress.
  • Inventory can be relieved for each component “on-time” as used in production.
  • Use Weight factors to automatically calculate material percentages of raw materials on the law tag.
  • Piecework rates will automatically feed into Manufacturing (Shop Floor).
  • Audit Reports to identify potential issues before posting models to production.

Scheduling

  • Many ways to schedule orders (by order number, by route, by ship-to state, etc.).
  • Automatically create Loads and Delivery Schedules during the scheduling process.
  • Ability to print all media (law tags, control tickets) with the stroke of a key.
  • Inquiry screens allow snapshot of where products are on the shop floor.
  • View quantities and percentages needed, done, and loaded for each run, order, and line item.
  • Daily totals broken down by item type, complete with production stats per hour.
  • Flexible inquiry filter allows each user to view production data per individual needs.
  • View pieces by Production Run, Order, or Item—filtered any way you like.
  • View details for each piece: operation statuses, lot numbers, employees, etc.
  • Tightly integrated with Orders, order changes provide immediate feedback to production.
  • Flexible; last-minute order changes can be applied to the schedule on-the-fly.
  • Historic daily production schedules retained for easy viewing.

Manufacturing

  • .NET-based web application; many stations share one license.
  • Full-screen, interactive interface leads employees through the scanning process.
  • Running balance of piecework pay and pieces produced.
  • Piecework automatically fed into Payroll module, with flexible controls by employee.
  • Teams can share an operation with piecework pay automatically split.
  • Time-clock control allows in/out hours to be set for each department, shift, and date.
  • Integrated intelligent time clock tracks hours, with incentive for correct clocking in/out.
  • Integrated FR Lot tracking.
  • Pictures of operations and products being produced.
  • Multi Lingual (English – Spanish).
  • Piecework, Bagging, and Shipping all from one web interface.

Shipping

  • Create loads on-the-fly using the Shop Floor Control Web Application.
  • One-Button bill of lading and invoice generation for any number of orders.
  • Shipped quantities on order updated as serial numbers scanned to truck.
  • Short shipments easily resolved to backorders, stock or cancel.
  • Historical load information, Bills of Lading can be reprinted.
  • Easy sequencing of orders on each load.
  • Delivery schedule in load sequence order, with contact info. and comments.
Browser functions
iPad inquiry window

We also provide browser based production inquiry functions. For example, the factory supervisor can walk the shop floor using a tablet device (such as an iPad) and determine what may be holding up order completion. Each serial number shows the last operation scanned, so a given piece can be tracked through each stage of production. Date and time for all operations for each serial number may be viewed, as well as a list of employees who performed each operation. If subassembly production is required, the status of subassemblies can also be viewed from this screen.

Testimonials

"Our family uses the internet constantly. However, we are dead in the water when it comes to figuring out and fixing computer problems. We recently had a serious problem with my computer, and also needed to switch to wi-fi, and didn’t know where to turn. There were over 80 service providers listed in our area. We had already tried two with disappointing results. We drove past Response Computer Group and went in. Our entire experience with this company has been fabulous. They are beyond a “10.” We highly recommend them and guarantee you won’t be disappointed."

Lennie Martin, Greenwood, DE

"Response Computer Group has been handling our data processing needs since 1989. When we were ready to computerize our operations, they were able to use the OSAS platform to customize software that allowed us to replicate our manual accounting system. Over the years we have worked together on several innovative solutions to help our company capitalize on new technologies. Probably the most ambitious was completed in 1997 when we installed Panasonic ToughBooks on our service vans and used Verizon's CDPD Network to transmit work orders to our vehicles. One important asset that Response brings to their customers is the ability to listen to the problem and develop a solution that fits the customer's needs - not the programmer's. We value our partnership with Response Computer Group and would highly recommend them."

George Sherman Corporation

"We began using OSAS in 1990. In our business we are required to meet certain regulations that can and do change. We must have an accurate method of recordkeeping for our serial number history and customer files, as well as inventory and customer maintenance. With OSAS and the modifications made by RCG we have the system we need to comply with any and all guidelines."

Kiesler Police Supply

"Wyoming Millwork Co. selected Open Systems from our inception and we haven't looked back since. The system has always had the integrated products we needed plus the flexibility to add enhancements as we grew. Response Computer Group has also been there from the beginning and we couldn't have done it without them."

Wyoming Millwork Co.

"We have used OSAS for many years now. With the ability to have the POS refined to our specific needs by Response Computer Group, it has worked very well for us in tracking our lumber and building materials sales and costs. We have found Response Computer Group to be prompt and knowledgeable in all of our computer needs."

The Adkins Co. Inc.

"Arranging the OSAS programs with a competent staff is the key ingredient of Response Computer Group. The software can be installed off the shelf i.e. General Accounting or fine tuned to Manufacturing consisting of Purchase Order, Inventory and Bill of Material/Kitting. Whether you need on-site or over the phone help, Response handles the package expertly."

Ultrachem Inc.

"Response Computer Group has the knowledge and background that has made OSAS come alive for our business applications and processes. With the addition of their suite of applications and programming skils that compliment OSAS, our business software has become an engine that drives and improves our productivity and efficiency."

Carolina Mattress Guild

"Working with Response Computer Group over the last 4 years has been a wonderful experience for us. There understanding of our operations and their willingness to constantly adapt software to our needs has made huge impact in our efficiencies. The programs created by RCG in the last few years have reduced our data entry requirements by at least 50% and the Manufacturing and Beyond for bedding application has given us complete control over our manufacturing processes. We are looking forward to continuing our successful relationship with RCG in the years to come."

Sleeptronic, Inc.

"Response Computer Group truly lives up to its name…responsive. They have the resources and knowledge to provide us the solutions and OSAS customizations we need. The staff at RCG makes us feel like we are their first priority, and support issues are handled quickly and efficiently. Working with RCG has been a pleasure."

Englander/TSP, Inc.

"Pleasant Mattress, Inc. started using RCG when we upgraded from OSAS 5 to 7. RCG has provided complete support for OSAS 7 and for the integration of a new Linux Red Hat Server which has made this transition a lot easier than it could have been. RCG has made many modifications to the OSAS Software to make it fit our mattress manufacturing needs. The customer service and technical support have been excellent.”

Plesant Mattress, Inc.

"My father started working with computers when a 5mb disk was the size of a refrigerator. He wrote our entire system. We have been working with Response Computer Group for at least 15 years - first with RECAP, then with UNIX, and now with Linux and OSAS. Dad wasn't happy about it, but he trusted the decision to work with RCG and we switched to OSAS on January 1, 2007. It has been working smoothly since. Phase 2 of our conversion will start later this year, and we look forward to working with everyone at Response on another smooth and well managed upgrade."

Hodges Badge Company, Inc.
Contact Info

Response Computer Group, Inc. © 2016
213 W. Liberty Way
Milford, DE 19963
Phone: (888)698-0875
Skype Connect: 99051000131621
Fax: 800-671-4790
info@rcgweb.com

Response Computer Group, Inc. BBB Business Review
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