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


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.


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


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


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


  • 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.


  • 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.


  • .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.


  • 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.


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George Sherman Corporation

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Wyoming Millwork Co.

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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.