Processing & Maintenance

iSmart Business Solutions Pvt Ltd.

IT Park, Plot No. 16 A, ‘B’ Block,
Cochin Special Economic Zone,
Kakkanad, Kochi, Kerala, India
Ph: (91) - 484 – 2413181
FAX: (91) - 484- 2413243
E-mail: [email protected]
URL: www.ibspl.com
 Index

Plant Maintenance System……………………………………………………...3

Fleet Management System……………………………………………………...7
Outgrower System……………………………………………………………...10
Weighbridge System…………………………………………………………...13
Rubber Processing System …………………………………………………….17
Palm Kernel Oil Factory System……………………………………………….21
FFB Processing System………………………………………………………...25
Fractionation and Refining Factory System……………………………………28
Tank Farm Management System………………………………………………32
Seed Production System……………………………………………………….35

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Plant Maintenance System

The HARVEST plus Plant Maintenance System takes care of all the operational details related
with the engineering section of an enterprise. The functioning of plants can be maintained through
this system. You can capture the estate or division details in which the plants are located. It
provides the workflow control for the major operations like job card, out sourcing, time sheet
schedule, and machinery process to control the logistics and provide the management with in depth
analysis of cost and management of resources.

It integrates all the operations of the logged in engineering unit to give an overall view. You can
schedule the jobs to be done in the plant in a specified date. The departments in the plant can raise
job requisitions, which is to be allocated after sanctioning. It calculates the labour cost of the
opened job cards created for doing the requested jobs. The costs are updated to the general ledger.
Also the jobs in the plant can be out sourced. This system keeps track, of the details of the
machines used in the plant, mainly for reporting purpose.

It integrates with other sections like Materials Management, Financials and Administration to
centralize processing. It also gives additional provisions required to optimize day-to-day
operations like checklist entry and its status maintenance, scheduling and breakdown maintenance.

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Main Features of Plant Maintenance System

The functioning of the engineering section of an enterprise can be done through the Plant
Maintenance System.

The main features of this system are:

1. Expenses incurred are distributed among various machineries: The scope of Plant
Maintenance System is to distribute the expenses incurred in the engineering units like wages
to the employees etc. to the various estate machineries which had under gone maintenance
work in the unit. It captures the data from estate/division on which the plant is located and
facilitates the functioning of the plant.

2. There is the provision to create multiple sections under the engineering unit/plant. You can
also set the in charges for these sections with in the corresponding engineering units or plants.

3. This system has the provision to create the job items under plant /engineering unit and we can
tag sections with the job items. Assets, machinery, equipment and vehicle together are termed
as job item, which need maintenance. The Job Item screen is used to define these job items in
the plant or administrative unit to perform the day to day activities.

4. This system helps to define the skill category in engineering system and allocate charge out
rate against that. This helps in identifying the skills needed for doing a particular task. This
rate is used for the costing of job cards.

5. Jobs are divided into tasks. In an engineering unit, a job can be divided in to different tasks.
There is the provision to define tasks in the section, via engineering unit. The tasks involved
will vary for each kind of service. You can also define the assets, procedures followed,
materials used, the man days utilized, and the tools and safe guards used to perform the task,
through this system.

6. Generate service schedules: This system helps to prepare maintenance schedule of

machineries in the engineering unit and outside the engineering unit/plant. According to this
schedule there is a provision to generate job requests/job cards, and alerts. There are mainly
two types of schedule handling in this system:

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Routine Service

Routine Inspection /Checks

7. Service Request: Jobs are done based on the requests for the job item made by the concerned
departments When a request for repair is reported with the engineering unit, further action is
taken on the request only after verification of request. There are different ways to create the
job request based on the request source. The request source types are:

Engineering unit

Administrative unit

Party

Schedule

Plant

8. Job card: This is the primary document for doing any maintenance work in the engineering
unit. All the major works will be carried out depending on this job card only. You can
outsource the work also.

9. Cost Estimation: The cost for doing a job based on the job cards prepared is calculated and
distributed against each of the machineries. The cost is estimated corresponding to the tasks
done, man hours utilized, material used and service charges. The total of these will be termed
as the estimated cost for the request. There are two methods for calculating the labor cost:

Based On Skill Category Rate

Based On Workshop Hourly Rate

10. Facilitates SIR generation: For all the registered jobs the respective engineering unit housing
clerk can allocate mechanic / worker to execute the task. The system will generate the
corresponding stores issue requisition in the Inventory Control System, based on this material
allocation.

11. The attendance details of the workshop employee can be entered, with respect to each Job card
and task.

12. There is the provision to enter the material consumption details and return the job cards.

13. Additional expenses incurred to job cards can be tracked.

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14. This system facilitates doing some small works with out job card.

15. Facilitates entering Disciplinary Actions: This system keeps track of the actions taken
against an employee for violating the operating procedures of the machinery assigned to him.

16. Provision to capture the day to day working of particular machinery in the engineering unit.
This information is used to giving alert for various service schedules.

17. There is the provision to create a Job Reception, Job Release, Other Expenses, Machinery
History, etc. based on the plant/engineering unit/admin unit.

18. Maintains Accident Log Book: Accidents may happen to the drivers or operators of the
company during working hours. The accident details such as date and time on which the
accident happened, type and the plant or engineering unit in which the accident happened etc.,
are maintained in all the plants to keep track of all the accidents.

19. Report Generation: Various reports are incorporated in this system after analyzing the
requirements of the end users. The main reports are Service schedule, Asset History, Costing
Report, Bills of Material, etc.

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Fleet Management System

The HARVEST Plus Fleet Management System provides the efficient way of managing the
running cost of the vehicles. This includes the accumulation of running, operating and
maintenance cost of an asset and distributing the same on the basis of the usage. Transport is one
of the important areas where assets are used and cost is distributed as per the usage.

Through this system you can categorize vehicles and can define specifications for vehicles. The
notifications for the expiry date of tax and insurance could be scheduled. Requisitions for vehicles
can be made for usage in a specified period. The vehicles can be allotted after sanctioning the
specified requisitions by an authority. Daily logs can be kept containing the usage details of
vehicles.

You can also record the maintenance details of vehicles through this system. The fuel and oil
consumption details of the vehicles can also be entered. Disciplinary actions can be taken on the
damage of vehicles. Various reports can be generated in this system.

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Main Features of Fleet Management System

The Fleet Management System facilitates the functioning of transport system in the company. This
system automates and thus simplifies all the functions related to transport and workshop.

The major features of this system are listed below:

1. This system provides provision to tag machinery to its usage and the standard performance
of the machinery.

2. The vehicles and machineries can be categorized based on their usage, size etc. A
hierarchy of vehicle classes can be created and maintained.

3. The expiry date of vehicle tax and insurance can be notified through either auto generated
reports or passing automatic journals.

4. This system records the transport activities within various locations.

5. Vehicle Requisitions: The vehicle requisitions can be made, in which the procedures of
vehicle requested for usage in a period can be entered. The vehicles will be allocated upon
sanctioning.

6. The vehicle allocation can also be done without requisition. When there is a request for a
particular vehicle and if that vehicle is already been allocated, then system will be able to
suggest with the available same type of asset.

7. Job Cards: The Job cards can be created containing details of job requests. All the major
works in the work shop will be carried out depending on this job card only.

8. Fuel and Oil Consumption: The details of fuel and oil consumed by the vehicles related
to a job can be recorded.

9. Daily Log: The Daily log of the machinery is used to track the day to day use of the
vehicles. With this you can also provide inputs to the employee remuneration calculation.

The total running hours and kilometers of vehicles in a day will be recorded
and the corresponding running cost can be calculated.

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The running cost distribution is based on the daily log entries in case the
vehicles are allocated for a short period.

If the vehicles are allocated for long period, it is not mandatory to have daily
log entries and the cost will be distributed on the basis of its allocation.

10. The details of vehicles hired from outside contractors can be entered through this system.
The company can enter into a contract with the contractors for the specified period. The
cost of the contract and also the details of charges to be deducted as maintenance cost can
be entered, if any.

11. Asset Allocation Codes (AAC): The asset allocation codes are the codes related to the
asset accounts of this system, which is linked with the specific account and analysis codes.
The day-to-day charging will be done to these codes. The expense journals will be posted
to the General Ledger System with the help of this linking.

12. Document Management: This system keeps track of the various documents related to the
machinery / vehicles.

13. You can run processes which compute the cost for each trip and charge the cost to the
beneficiary. There are various options to compute the unit rate, which constitutes the basis
for getting the cost for each trip. This can be fixed based on the type of the machinery and
cost distribution policy.

14. Report Generation: You can generate reports for viewing the cost for each trip and
performance of machineries in terms of fuel efficiency and out put.

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Outgrower System
The HARVEST Plus Outgrower system is designed to customize the activities related to the
contract with the outgrowers. The outgrowers are the party that supplies the raw material for the
manufacturing of the oil palm for the specific companies where in they utilize their resources for
the production of fresh fruit bunches.

Through this system you can define the categories for out growers and can group various out
growers into these categories. You can also define the market rate of raw materials with respect to
its effective date.

The details of the contract can be prepared, sanctioned and cancelled through this system. Also the
details of the renewing contract can be prepared, sanctioned and cancelled. You can maintain
payment advice memos for the contracts prepared through this system.

You can also calculate and print the periodic crop projection based on the delivery schedule of out
growers. The system has the provision to generate the reports for the corresponding transactions
that takes place.

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Main Features of Outgrower System
The system maintains all the contract details related to out growers of the company.

The major features of this system are listed below:

1. The Category Definition screen is used to define the various categories of out growers
based on different factors such as location of supplier, quality and the type of the materials
supplied to the company etc.

2. This system is designed to customize the activities related to the contract made with the
out growers. The details of the contract can be prepared, sanctioned and cancelled.

3. The Outgrower Categorization screen is used to categorize the specific outgrowers or the
smallholders based on different category criteria such as location, material quality,
material supply etc and based on the specified category.

4. The market price for the raw material is again subject to changes based on the market
trend. The Market Price screen is used to define the price for the raw material. The date
from which the newly defined market price is in effective can be entered.

5. Supply Contract: Through this section the supply contracts can be prepared, sanctioned
and cancelled.

The Preparation screen is used to enter the contracts details for supplying raw
materials. You can enter the terms and condition of the contract, bonus details,
raw material delivery schedule and payment schedule related to the contracts.

A bonus based on the supplied quantity for a month can be paid to the out growers
based on the quality of the raw material they have provided. Also we can define
the Bonus Rate per KG for the FFB supply during that month.

We can also define the additional charges or discounts, payment schedule,

delivery schedule and the terms and conditions of the contract while creating the
contract.

The Sanctioning screen is used to sanction or reject the supply contracts entered

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 through Preparation screen. All the unsanctioned contracts as on the specified
date will be displayed in the grid. The remarks regarding the sanctioning or
rejection can also be entered.

The Cancellation screen is used to cancel the contracts that have been sanctioned.
The reason for cancellation can also be entered.

6. Renewing Contract: Provision to extend or renew a contract based on the company’s

policy. This section contains screens which allow you to enter the details regarding the
extension of the supply contracts. You can also sanction and cancel the extended contracts.

Contract nearing completion can be renewed or new contract can be created. The
period of the selected contracts can be extended.

Contract can be renewed only once and modification of contract condition’s of the
renewed contract to that of the original contract is not possible.

7. The quality and quantity of the good’s supplied can be known through the supplier
register.

8. A payment advice memo can be generated for the out grower. The Payment Advice Memo
screen is used to generate a memo based on which the payment is to be made to the
outgrowers. The payment to be made to the outgrower is based upon the weigh bridge
docket and contract details.

The journal will be posted in General Ledger System for the amount generated in
payment advice memo.

9. Crop Projection: Provision to do crop projection based on the delivery schedule

mentioned in the supply contract.

10. Report Generation: Various important reports can be generated such as Expired
Contract, Contract wise supply Register Summary as well as details, Payment Advice
Register Details, and Due for Payment Process etc.

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Weighbridge System

The HARVEST Plus Weighbridge System facilitates the functioning of weighbridge installed in a
mill or factory of an estate. The weighbridge installed may be a manual or an electronic
weighbridge. The various vehicle categories, vehicles and the capacity of materials that can be
carried by each vehicle category can be defined in this system. The type of materials weighed and
their source or destination can also be tagged through this system. The type of vehicles that can be
allotted to a driver can be tagged in this system. The average bunch weights of the crops arriving
from own field, block or out grower’s farm can be captured here.

You can capture the weight of the material and vehicle arriving for weighment while performing
the first weighment and second weighment. The calibration details of the weighbridge and vehicle
/ cage weight are also recorded. The details of blacklisted vehicle and driver can be specified
through this system. You can also track the details of the quality of the crops arriving from own
field / block or out grower’s farm. Weighbridge system also produces all the desired reports
required for monitoring and controlling the system.

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Main Features of Weighbridge System

The Weigh Bridge System facilitates the functioning of weighbridge installed in the mill or
factory. Incoming and outgoing materials (products) are weighed on weighbridge before they are
accepted or dispatched.

The major features of this system are listed below:

1. The weighbridges defined through Weighbridge screen can be a manual weighbridge or an

electronic weighbridge, as your requirement.

Electronic weighbridge measures the weight and converts it in to digital signals

and these signals are captured by computer through ports and the data will be
stored for analysis purpose. The technical data transfer settings for the electronic
weighbridge can be defined using this screen.

There is provision to do manual weighing in absence of electronic weigh scale.

2. The HARVEST system can handle more than one Weigh Bridge System for a location.

3. You can set the cut off time for the business transaction, which refers to the start time of a
business day.

4. The Vehicle screen is used to define various vehicles that come to the weighbridge. It
facilitates in ensuring only authorized and known vehicles coming to the weighbridge.
You can define the standard tare weight of vehicle. If there is deviation from the defined
standard weight, system pops up an alert message.

5. Linking: This section contains options, for linking various entities in this system, which
helps for the accuracy of the data entry.

The Weighbridge - Material Linking screen is used to define the materials that
can be weighed in the specified weighbridge.

The Vehicle - Material Linking screen is used to define the materials that can be
transported in the specified vehicle.

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The Material - Source / Destination Linking screen is used to tag the source/
destination for the specified material belonging to various categories.

The Source / Destination - Material Linking screen is used to tag the specified
source/ destination to the materials belonging to various categories.

The Driver/Helper – Vehicle Linking screen is used to tag the specified

driver/helper to the vehicle belonging to various categories.

6. ABW: The details of the average bunch weight of the crops from own field / block defined
through this section.

The Own Field / Block ABW screen is used to define the average bunch weight of
the crops from the own division or field / blocks for a specified period. If the
ABW is defined at the division level, then all the underlying field / blocks would
have the same average bunch weight.

The ABW Range screen is used to define the rate per unit, for the different bunch
weight ranges of the crops. Through this option, you can also specify the period
for which this rate is applicable.

7. The ABW for out grower can be entered through the Quality Analysis screen. Quality
analysis is mandatory if the material is coming from an out grower. The details of the fruit
bunches arrived from own field / block and out grower’s farm such as grade, average
bunch weight can be captured using this screen. The total bunches and loose fruits arrived
from the out grower’s farm, the details of the samples and penalties can be entered using
this screen.

8. Locomotive: Locomotive engines pull the rail cages carrying raw materials. Locomotive
type vehicle can be defined in the Vehicle Category screen. The vehicles tagged with these
vehicle categories will only be populated, in the Locomotive No field for which weighment
has to be done through “Transaction / Cages Weighing”.

9. You can enter the weighment details of rail cages on special weighbridge, where railway
lines are available on weighbridges.

10. In the case of Locomotive weighment, tare weight is not measured along with all the
weighing. Instead, fixed tare weights of the rail cages and chassis are used.

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11. For Locomotive weighment, Trip Number is generated automatically by this system and it
will get reset on every day.

12. User defined vehicle format is given that is done using the regx expression builder.

13. Blacklisting: This section contains options, which allows you to blacklist the vehicles or
drivers. A vehicle can be blacklisted due to technical reasons such as non calibration of the
vehicles in spite of the warnings given by the system or due to wear and tear of the
vehicle. A driver can be blacklisted due to their poor service, lack of following the rules
and regulation of the company etc.

14. The Revoke Blacklisting section contains options, which allows you to revoke the
blacklisted vehicles and drivers.

15. Provision to identify vehicles which will be used for Weighing

16. The last calibrated date for each weighbridge and vehicles can be recorded.

17. Inspection is included to identify the unripe and rotten bunches.

The Grade Range Definition screen is used to define the grade ranges for the
items. The maximum percentage of items that are eligible for penalty or that can
be rejected can be specified through this option.

The out growers penalty details can be recorded through Quality Analysis screen
of this system.

18. Capable to generate notification messages using Harvest Pop messaging system.

19. Report Generation: Various reports are included in the system such as Weighing Docket
and Ticket Printing, Raw Material Arrival Register, Turn Around Time, Block wise arrival
register, Transporter Register etc.

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Rubber Processing System

The HARVEST Plus Rubber Processing System facilitates the functioning of crumb rubber factory
of the company. This system handles the arrival of raw materials, tracks the inputs to various
production lines, processes the raw materials and dispatch the finished goods to various
destinations. The quality assurance of the products is handled in this system and provides
traceability of the finished goods. Various reports based on the stock availability such as daily,
monthly, stock adjustment details etc can be generated in this system.

The raw materials such as latex and lump are arrived to the factory for processing. The latex
arrived from the field, in latex tanks are coagulated, crushed into small particles and dried to make
crumb rubber. The dried rubber is pressed in the hydraulic presser to make bales and packed in
pallets. Samples are collected from every 4 bales in a pallet, and are analyzed to measure specific
quality parameters. The bales packed in pallets are moved from factory to the warehouse. The
stocks of rubber as well as dirty rubber are maintained separately in the warehouse. Based on the
dispatch instructions from the head office, factories dispatch the goods to customer place directly
or to the warehouses at bulking stations.

The details of the machinery, fuel and lubricants required for the rubber processing can be
captured in this system. Also the details of electricity consumption from the government grid lines
as well as generators will be captured separately in this system. You can generate all the desired
reports required for the monitoring and controlling of this system.

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Main Features of Rubber Processing System
The Rubber Processing System facilitates the functioning of crumb rubber factory of the company.
The raw materials such as latex and lump arrived to the factory are undergoing various processes
to make crumb rubber.

The major features of this system are listed below:

1. The various processes from the arrival of raw materials to the manufacturing of crumb
rubber are handled in this system.

2. This system records the details of raw materials arrived to the factory for processing.

The raw materials processed at the rubber processing units will produce the
different types of semi-finished and finished goods.

3. The details of the latex arrived from own estate or out grower’s estate are maintained in
this system.

The volume of latex in the tank is measured by the dip measurement height
and corresponding volume in liters is derived from the calibration tables for
each tank.

4. DRC Content: The dried rubber content of the latex arrived is recorded in this system.

The dried rubber content of the latex arrived is measured using the DRC meter
(Lactometer). The rubber content availability in latex is calculated as Litres *
DRC %.

5. This system keeps track of the lower grade rubber such as lump and scrap arrived from the
estates.

6. Coagulation of Latex: The details of the coagulation of latex done at the processing
station are included in the system.

The latex arrived in the latex tanks are kept one day for coagulation. The latex
from the carrying tanks is first poured into bulking tanks, and then made to
flow into the coagulating pits. At both the stages chemicals such as HNS and
formic acid are mixed with the latex.

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7. Crushing and dehydrating of lower grade rubber: The details of crushing and
dehydration of lower grade rubber is included in the system.

The lump and scrap collected from the field is washed, soaked and dehydrated
for about five days before further processing. The soaked lower grade rubber
is spread on a drying floor marked with different sections and rows.

8. Drying: This system includes the details of rubber granules dried in the driers.

The coagulated latex is crushed into small particles called granules. The
rubber granules are stored in drying boxes and dried in driers.

9. Reprocessing of Dried Rubber: The process of subsequent drying of partially dried

rubber is included in the system.

Reprocessing is the process of subsequent drying of partially dried rubber.

10. The details of the different types of pallets used to pack the bales are included in the
system.

11. Packing Bales: The details of the bales packed in pallets are recorded in this system.

The dried rubber is pressed in the hydraulic presser to form bales. The bales
are normally pressed to form pallets. The bales are weighed in weigh scales
and packed in pallets. The pallets are numbered sequentially.

12. Sample Collection: Frequency of conducting the analysis of each product and the
quantum of sample are collected at different stages and intervals during processing.

Samples are collected from every 4 bales in a pallet, and are analyzed to
measure specific quality parameters.

13. Transferring products from Factory to Warehouse: The system keeps track of the
transfer of products from factory to warehouse.

14. The stock of rubber as well and dirty rubber is maintained separately in this system.

15. Dispatch of products: The details of dispatch of products are also maintained in this
system.

The products can be dispatched to the customer place or to the bulking

stations, as per the advice from head office.

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The dispatch note is prepared and attached along with every dispatch.

The bulking station sends confirmation reports on product shipments done to

respective factories.

16. Machinery Usage: This system captures the usage of lubricants and fuel used for the
operation of each machinery.

The number of operating hours of the machinery and the details of the
chemicals added to the products are captured in this system.

17. Electricity Consumption: The details of the electricity consumption at the processing
units are captured in this system.

The details of electricity consumed from the government grid lines as well as
generators are recorded separately in this system.

18. Report Generation: Various reports incorporated in the system such as Daily Production
Report, Stock Verification, Dispatch Report, Stock Report, Machinery Usage Report,
Electricity Consumption Report etc.

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Palm Kernel Oil Factory System

The PKOF (Palm Kernel Oil Factory) processes the PK (Palm Kernel) and produces CPKO (Crude
Palm Kernel Oil) and PKEC (Palm Kernel Expeller Cake). The HARVEST it 2.0 Palm Kernel Oil
Factory System facilitates the details of palm kernel processing at the PKOF.

The arrival details of palm kernel to the factory can be recorded. The details of delivery order
issued to the load arrived, entry ticket, quality analysis of sample and weigh bridge weight and the
variance in weight can be entered. The stock measurement of palm kernel and crude palm kernel
oil in the factory can be done with the help of this system. The dispatch details of final products,
produced in the factory can be entered for generating the dispatch note.

Daily stock measurement for every product can be recorded and the system will calculate the
extraction percentages of the products. The quantity of electricity and water consumed in a month
can be estimated with the help of daily consumption details entered to this system. The
reconciliation of stock in the factory can be done. You can generate various reports containing the
production details in the palm kernel oil factory.

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Main Features of Palm Kernel Oil Factory System

The PKOF System facilitates the automation of entire activities of palm kernel oil factory.

The main features of this system are listed below:

1. This system captures all the details right from the palm kernel arrivals till the dispatches of
finished products such as CPKO (Crude Palm Kernel Oil) and PKEC (Palm Kernel
Expeller Cake).

2. Palm Kernel Arrival: This system caters the functionality of palm kernel, arrives from
the palm oil mill and also from own estates.

 The details such as quality analysis details and product weighment details can
be entered.

 Daily receipt details report can be generated based on these entries.

3. Section: This system has got provision for capturing various sections of production in
PKOF.

 Different sections like Iron Trap, Rolling Mill, Flaking Mill, Conditioner, Screw
Press and Press Filter are used for processing the PK; there are no semi-finished
products that need to be measured in between the sections.

 The system captures all the process happening in the production of finished
products from raw materials.

4. Storage and Measurement: The storage and measurement details of palm kernel and
finished products in the factory can be recorded.

 Arrivals and dispatches are not allowed during tank measurement.

 Based on various entries the system calculates the total weight of palm kernel in
silo, weight of crude palm kernel oil in tanks and total quantity of palm kernel
expeller cake.

5. Daily Production: Daily production quantity of each product is derived from the
difference between the stocks of current working day and previous working day.

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6. Quality Analysis: The details of quality analysis tests performed at various levels of
production can be entered through this system. This system can generate reports based on
the variety of quality tests done.

7. Extraction Ratio: This system derives separate extraction ratio for finished products such
as CPKO and PKEC, from the daily production details of PKOF.

8. Dispatch Details: You can enter the dispatch details of CPKO and PKEC based on the
contract with party. The partial supply based on the production is also possible.

 In case of CPKO, it may be transferred to the FRF for the production of RBDPKO
and Lauric Fatty Acid.

 For dispatches to third party, information of contract, signed at head office is sent
to the PKOF and also to the transporter in the form of a delivery order.

 The loading instruction details, quality analysis, weighment details and security
seal and lock details of the dispatching product can be entered.

9. The PKOF system is totally integrated with the weighbridge system to get all the weighing
done during various processes in the factory.

10. This system keeps tracks of all supplies to different parties as well as different estates and
bulking stations (warehouse).

11. The dispatch quality analysis can be done based on the delivery order and contract with
third parties.

12. Electricity & Water Consumption: The details of electricity and water usage can be
recorded through this system. The charges to be paid for electricity and water consumption
can be calculated. Apportioning of the same can be done based on the usage.

13. Stock Reconciliation: This system has provision for doing the stock reconciliation based
on the dispatches and actual stock received at various destinations. Total differences in
quantity can be adjusted at the end of the month to the current month’s production of the
product and in the production losses of the PKOF.

14. Machinery Maintenance: The system maintains section logs to analyze the efficiency of
the machines used in the palm kernel oil factory. The details of maintenance done for the
machines and also their spare parts requirements can be recorded.

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15. Stock Transfer: It is possible to record the transfer of stock from one tank to another. In
PKOF, transfer of stock from daily tanks to CPKO storage tanks is routine process.

 Stock measurements of the storage tanks which are taken before and after
transfer can be entered through this system.

 Transferred Quantity and Transit Loss: With the help of this entry the
system calculates the amount of transferred stock and also the transit loss.

16. Report Generation: Various sets of reports can be generated through this system, to
analyze different stages of production. The reports help you to know more about
productivity, factory extraction rate etc.

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FFB Processing System

The HARVEST Plus FFB Processing System automates the process carried out at different sub
sections of sections and stations. This system will capture various transactions happening at the
processing unit starting from the arrival of FFB (Fresh Fruit Bunch) to the dispatch of CPO (Crude
Palm Oil) and PK (Palm Kernel) to various destinations. Stock and movement of FFB, CPO and
PK is maintained in this system. It captures the details of the quality analysis conducted at the mill
laboratory. The machineries, generators and electricity used will also be maintained in this FFB
Processing System. The stock reconciliation can be done under the process of this system. All the
basic settings needed for the smooth functioning of this system and the opening quantities of the
product stock and equipment can be maintained. FFB Processing System produces all the desired
reports required for the monitoring and controlling of this system.

The raw materials such as fresh fruit bunches are arrived to the mill for processing. The FFB
arrived from the different suppliers or own estate is processed to make CPO and PK. Samples are
collected and lab tests are conducted in the process sub stations. The stock is transferred from
source to destination tanks. Based on the delivery orders from the customer, mill dispatch the
products to customer place directly or to the warehouses at bulking stations.

The details of the machinery, fuel and lubricants required for the FFB processing can be captured
in this system. Also the details of electricity consumption from the electric meters as well as
generators will be captured separately in this system. You can generate all the desired reports
required for the monitoring and controlling of this system.

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Main Features of Fresh Fruit Bunch System

The FFB Processing System facilitates the automation of entire activities of Palm Oil Mill. This
system captures all the details right from the fresh fruit bunches arrival till the crude palm oil
dispatch.

The major features of this system are listed below:

1. The FFB system caters the functionality of the fresh fruit bunches arrived from different
suppliers as well as from the own estates.

2. This system has got provision for capturing various stages of production in the palm oil
mill. It captures all the process happening in the production of finished products from raw
materials.

3. The details of the samples of materials collected to conduct the lab tests can be captured in
this system.

4. The quality analysis tests at various levels of production can be done through this system.
This system can generate reports based on the variety of quality tests done.

5. The details of the measurement of CPO and Kernel can be captured in this system.

6. Through this system, you can enter the quantity of the stock transferred from source to
destination.

7. Separate extraction ratio for own FFB and third party extraction ratio can be derived from
daily production details of POM (Palm Oil Mill).

8. There is a provision for dispatch of CPO based on the contract with party in this system.
Partial supply based on the production is also possible.

9. FFB is totally integrated with the weighbridge system to get all the weighing done for
POM like FFB arrival and CPO/PK dispatch.

10. This system keeps track of all supplies to different parties as well as different estates and
bulking station (warehouse).

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11. The details of dispatch of products are also maintained in this system.

The products can be dispatched to the customer place or to the bulking

stations, as per the delivery order received.

The dispatch note is prepared and attached along with every dispatch.

12. The details of the electricity consumption at the processing units are captured in this
system.

The details of electricity consumed from the electric meters as well as

generators are recorded separately in this system.

13. The details regarding the operations of the turbines can be captured in this system.

14. This system has provision for doing the stock reconciliation based on the dispatches and
actual received at various destinations.

15. This system maintains machinery running log to analyze the efficiency of the machines
used in FFB processing.

16. This system takes care of the various actives in the mill like ‘Tank measurement’,’ Stock
Transfer’(From one tank to other), Dispatching using pipeline.

17. Various sets of reports to analyze different stages of production to know more about mill
productivity, Factory extraction rate etc.

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Fractionation and Refining Factory System

The FRF (Fractionation and Refining Factory) processes CPO (Crude Palm Oil) and produces
RBD Olein (Refined Bleached and Deodorized), RBD Stearin and Fatty Acid as the main finished
products. In some cases, as per the customer demand, we are processing CPKO (Crude Palm
Kernel Oil) and produces RBDPKO (Refined Bleached and Deodorized Palm Kernel Oil) and
Lauric Fatty Acid as the finished products. The HARVEST it 2.0 Fractionation and Refining
Factory System facilitates the automation of the entire activities related to refinery.

This system maintains the details related to the refining process right from the CPO arrival to the
factory. The system prepares an entry ticket when a new consignment arrives and also creates a
weighbridge ticket. The quality tests are done immediately after the receipt of the raw material.
You can record the stock details of CPO in the storage tanks. The production lines and the
machinery sections in the factory which perform specific jobs in the process cycle can be defined.
The sections include pre treatment, refining, fractionation, press filter etc. The details of fatty acid
stored in the tanks can be entered on a daily basis. The details of quality control tests performed on
the products can be entered.

The extraction ratios of the products can be calculated using this system. The details of dispatching
products from the factory, machinery maintenance, water consumption and power consumption
can be recorded. The system also enables you to view the reports containing details related to
various processes in the factory.

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Main Features of Fractionation and Refining Factory System

The FRF (Fractionation and Refining Factory) System facilitates the automation of entire activities
of refinery. In FRF, processing of CPO (Crude Palm Oil) is done. But in some cases, CPKO is also
processed.

The main features of this system are listed below:

1. This system captures all the details right from the CPO/CPKO arrivals till the finished
product dispatches of RBD Olein, RBD Stearin, Fatty Acid, RBDPKO etc.

2. This system caters the functionality of CPO/CPKO arrival from different suppliers and
from the own estates. The details such as entry ticket issued, weighbridge weight and CPO
analyzing details can be recorded.

3. The measurement details of the arrived oil in the storage tanks can be entered which
includes the temperature and height of oil in the tank.

4. A production line refers to one set of machineries that processes CPO. The production
lines in the factory can be defined.

5. This system has got provision for capturing various sections of production in refinery. It
captures all the process happening in the production of finished products from raw
materials.

You can enter the details of sections like pre treatment, refinery, fractionation etc.

Separate processing reports are prepared for each production line.

Storage and measurement details of various products can be entered.

6. The quality analysis tests at various levels of production can be done through this system.
This system can generate reports based on the different quality tests done.

7. The extraction ratio for products such as RBD Olein, RBD Stearin, Fatty Acid, RBDPKO
and Lauric Fatty Acid can be derived from daily production details of FRF. There are
separate daily production details for CPO and CPKO.

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8. There is provision for entering details of dispatch of RBD Olein, RBD Stearin, Fatty Acid,
RBDPKO and Lauric Fatty Acid based on the contract with party. Partial supply is also
possible based on the production.

9. This system is totally integrated with the weighbridge system to get all the weighing done
such as CPO/CPKO arrival from other estates and RBD Olein, RBD Stearin, Fatty Acid,
RBDPKO and Lauric Fatty Acid dispatches.

10. This system keeps track of all supplies to different parties as well as different estates and
bulking stations (warehouse).

11. The quality analyzing details of dispatched products can be recorded based on the delivery
order and contract with third parties.

12. You can enter the details of electricity and water consumed in the factory. The system will
calculate the charges of the consumption and it will apportion the same based on the
usage.

13. This system has provision for doing the stock reconciliation based on the dispatches and
actual received at various destinations.

14. This system maintains section logs to analyze the efficiency of the machines used in the
factory.

15. This system takes care of the various activities in the refinery like tank measurement.

16. In all the cases, the daily production is calculated for all the days even though there is no
production at all. During the daily production calculation, we will get the Production
details and the extraction rates, production losses and the loss percentage details etc. There
are separate daily production UIs in FRF for CPO and CPKO.

17. FRF is also related with INV module and we can define a sub store of INV in FRF
Settings. We can define the additives and process chemicals consumed in each process
section for the processing and the total consumption of additives and process chemicals
will be the issued quantity of these from the sub store tagged for INV.

18. Arrival Quality Analysis and Dispatch Quality Analysis are mandatory before doing the
daily production calculation.

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19. Report Generation: Various sets of reports can be generated to analyze different stages of
production which enable you to know more about refinery productivity, factory extraction
rate etc.

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Processing And Maintenance
Tank Farm Management System

Tanks are normally used to store the various oil palm products. The HARVEST Plus Tank Farm
Management System deals mainly with stock of products in a tank. The details can be kept estate
wise using this system. The local sale and export details of products can be maintained through
this system.

You can define storage tanks used in the estates through this system. Daily measurement details of
tanks can be entered. This system identifies and suggests ideal storage tanks. You can enter estate
wise details of each product through this system. This system can maintain the oil movement
details through trucks, ships and pipelines. The details of export formalities of products can be
maintained. The lab results of products in the tank can be recorded.

This system tracks the delivery order details of local sale and also shipping. It interacts mainly
with HARVEST Plus Weighbridge System if the dispatch is done by truck and integrates with
Sales System while shipping the products.

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Main Features of Tank Farm Management System
This system facilitates the shipping and local sale of the products from the ware houses of the
company.

The major features of this system are:

1. This system facilitates the warehouse system at port.

2. This system can handle rubber and oil products. It is able to keep track of the arrival and
dispatch of the goods.

3. You can define storage tanks of products. The details of calibration of tanks such as table
correction, volume calibration, and coefficient factor at different temperatures could be
captured.

4. The coefficient factor and density of products at different temperatures can be recorded.
This will be useful when calculating the weight of the product, which can be obtained by
multiplying volume with the density of the product at the measured temperature.

5. This system can handle both export and local sale. Stock movement is done based on the
instructions from centralized sales department.

6. You can capture the receipt details of products at the bulking station.

You can enter the product arrival details on the basis of weighbridge tickets
created through the Weighbridge System.

If the products are arrived to the bulking station by ship, then the dispatch note
details can be entered.

An acknowledgement can be created after receiving the products at the bulking

station.

7. This system is able to track the stock of product separately for each delivery note.

8. The daily tank measurement details can be recorded and maintained in this system.

9. You can enter the delivery order details received at the bulking station for local sale of
products. This can be prepared against a contract.

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10. This system is capable of handling the oil movement through truck, ship and pipe line. It
also integrates with weighbridge system for tracking truck movements.

11. At time of oil dispatching by ship we can keep track of the tanks on which the oil is filled
and system generates the documents related to the export formalities in the prescribed
format.

12. Storage Units: Volume of the product is calculated from the height of product in the tank
using the calibration charts; For attaining the quantity of the product we are considering
the temperature and specific gravity of the product at measuring temperature and the
volume.

13. It is possible to keep the maintenance history of the tanks through this system.

14. Rubber: stock movement we are tracking Grade wise, Pallet Type Wise. And keeping
pallet wise information with production & Export pallet numbers. And generates the
documents relating to export formalities.

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Seed Production System

The HARVEST Plus Seed Production System automates the processes involved in the production
of oil palm seeds. Apart from the commercial seed production, this system also automates the
research and development processes associated with the organization. Systematic research
processes helps in generating new seed families with high quality.

The seed production process can be classified into seven phases. The first phase involves finding,
bagging and harvesting the male flowers. In the second phase the pollens are collected from the
male flowers and stored in refrigerators. Then the pollens are prepared for pollination. The third
phase starts with finding female flowers and bagging them. Then crossing is done by artificial
pollination of male pollen on female flowers. The due bunches are harvested and transported to
bunch processing laboratory. In the fourth phase the harvested bunches undergo a series of
processes in the bunch processing laboratory. After these the seeds are collected from bunches and
sorted. Then embryo test is done on the sorted seeds. In the fifth phase the seeds that pass the
embryo test are kept in seed store and these seeds undergo various pre-germination processes in
this store. Then comes the sixth phase in which the seeds get germinated and the germinated seeds
are collected. And in the last phase the germinated seeds are sorted, packed and dispatched.

In each step on each of the above said phases, thorough quality checking is done, in order to
ensure, high quality of the produced seeds. If the flowers, seeds or bags used in the various stages
did not pass the quality checking, then they are destroyed at that time itself. This system provides
the users with a list of reports and checklists that helps in optimizing the day-to–day activities.

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Features of Seed Production System

The Seed Production system computerizes all the processes that are related to the production of
seeds in the company. The main processes in seed production are Pollen Collection, Pollination,
Harvesting, Production Planning For Seeds, Germination, and Packing and Dispatching. The
features of this system are classified according to the processes. The main features of this system
are:

Pollen Collection

• Male Flower Details

You can keep track of the details of the Pisifera palms and the availability of male flowers
yet to blossom in the palm through this system.

• Bagging Bag Administration

Bagging is the process of covering the flowers with bags in order to protect them from
getting contaminated from wild pollens. Details of bagged male flowers can be obtained
from this system. The quality of the bags, used for the bagging process can be specified
through this system. Also the details of the bags issued and received can be maintained
through this system.

• Quality Checking

The quality of the bagging done on the male flowers and the details of the flowers
destroyed due to poor quality can be identified through this system.

• Harvesting Details

This system facilitates notifying the workers with the list of male flowers that are to be
harvested.

• Pollen Extraction Details

The details of the harvested male flowers, pollens collected and sieved pollens can be
maintained through this system.

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 • Viability Checking

This system provides the facility to calculate the viability percentage of the pollen and the
moisture content percentage of the pollen collected. These calculations are done on a
sample of pollens. The details of the pollens rejected after the viability process is also
captured.

The viability percentage is calculated using the formula:

(Total number of live pollen in the sample/ Total number of pollen in the sample)
* 100.

The Moisture content percentage is calculated using the formula:

(Weight of moisture content in pollen sample / Weight of pollen sample) * 100

• Bottling of Pollen (Barcode for Bottle Numbers)

The pollens that are accepted after the viability test are kept in a bottle and barcodes are
given to these bottles. The details of the barcodes assigned to the bottles can be maintained
through this system.

• Details of Imported Pollen from other countries

Sometimes the bottles needed for storing the pollens are imported from other places. In
such cases the same details can also be updated in the corresponding records.

• Pollen Stock Maintenance

The stock of pollen available each day can be obtained from this system. Also the details
of the pollen that come into and go out of the stock are updated on a daily basis.

• Details of Flower Destruction

This system keeps track of the flowers that are destroyed after each stage of pollen
collection.

Pollination

• Female Flower Details

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 This system facilitates keeping the details of the female flowers that are needed for
artificial pollination and seed production.

• Female Flower Bag Administration

Bagging the female flowers is done to avoid natural pollination. Bagged female flower
details can be obtained from this system. The quality of the bags, used for the bagging
process can be specified through this system. Also the details of the bags issued and
received can be maintained through this system.

• Quality Checking

The quality of the bagging done on the female flowers and the details of the flowers
destroyed due to poor quality can be identified through this system.

• Matching Process

Matching refers to finding the best suited pollen for a female flower according to the
crossing plan. This system provides a list that lists, in detail the female flower and male
pollen matching results.

• Pollination Order based on the matching details

This system generates the order for pollination, using the data generated from matching
process.

• Pollination Details (implementation of Barcode for Pollination No)

This system generates a label based on the pollination order and these labels are fixed on
the female flowers, to identify the pollination done on them.

• Quality Checking On Pollination

This system provides the list of palms to be inspected daily for quality checking, based on
the pollination order data.

Bunch Harvesting
• Harvesting Details of Bunches

This system generates the list of palms to be harvested and issues the order for harvesting.

• Bunch Processing Details(Chopping, Stripping, Depulping, Sorting)

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 In the bunch Processing Laboratory, the harvested bunches must undergo certain processes
such as, chopping, stripping, depulping and sorting, before seed preparation. The daily
activity recording at the Bunch Processing Laboratory as well as the details of the
incentives for various workers at various stages in the Bunch Processing Laboratory can
be maintained in this system.

• Seed Stock Maintenance

The stock of seed available in the store can be obtained from this system. The details of
the seeds that come into and go out of the stock are updated on a daily basis. The detailed
list of seeds in the store, seeds in the store dark room, seeds in the store heat room, etc. can
be viewed in this system. Also this system provides the details of the stock of expired and
ready to sale seeds.

Production Planning For Seeds

• Production Order

This system prepares the production plan for the organization, specifying the quantity of
seed to be produced in a year. This includes the quantity of seed to be produced in each
working day in the year. Apart from this, another plan is prepared for every month, which
contains the category wise estimation of seed production. According to this plan, the
system prepares production order.

Germination

• Details of various germination processes (Soaking, Fungicide application, Aeration,

Heating, Sampling etc.)

This system maintains the details of each process involved in germination. The main
processes in germination of seeds are soaking, fungicide application, aeration, heating and
sampling. The details of each of these processes done on the seeds can be tracked through
this system.

Packing and Dispatching

• Collection and Selection Process of Seeds

• Packing Details (Implementation of Barcode for Bag Numbers)

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 • Details of Dispatching

This system maintains the details of the seeds dispatched to the customers according to
their requirements. Along this, the acknowledgement card for goods receipt from the
customers is also prepared.

• Destruction of Expired Seeds

Main Reports

Various reports are included in this system to enhance its working. Also reports are
incorporated according to the end user requirements. Some of the main reports in this
system are:

• Bagging failure report

• Bunch processing report

• Bunch Production Activity Report

• Bunch production summary report

• Category wise seed prod status

• Daily Summary Quality Analysis

• Germination ageing report

• Pollen Stock Reports

• Pollen distribution report

• Pollen Production

• Pollination failure report

• Pollen Harvest summary

• Production report

• Seed Stock Report

• Seed Status

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 • Seed Status Germination

• Seed Status losses

• Quality Checking Reports

• Male & Female Flower Finding Report

• Male & Female Flower Bagging Report

• Bunch Harvesting Report

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