Complexity in Industrial ERP: Getting Back to One Version of the Truth


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Multi mode manufacturing and increased diversification in business models across all industrial sectors is straining the capabilities of many standard enteprise resource planning (ERP) products. This study from IFS North America and Mint Jutras reveals how some highly complex companies need to run as many as seven different types of enterprise applications. Engineer to order manufacturers, engineering procurement and constrution contractors and process manufacturers proved to be the most complex.

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Complexity in Industrial ERP: Getting Back to One Version of the Truth

  1. 1. Complexity in Industrial ERP: Getting Back to One Version of the Truth November 2012
  2. 2. BackgroundIn September 2012, a study was conducted amongexecutives and professionals at middle market to largemanufacturers to better understand how well current ERP This study wasoptions meet the needs of companies in selectedindustries conducted by IFS North AmericaThis study illuminates: and Mint Jutras,• How companies in a number of industries face an independent increasing complexity by way of diversification research-based towards more demanding business models. consulting firm• The fact that integration is key to supporting these that specializes in new and complex business models and processes. analyzing the• The degree to which more complex industrial business impact businesses are now forced to rely on a variety of different enterprise software applications. This of enterprise increases license and maintenance cost and non- applications. value added work while decreasing efficiency.
  3. 3. Methodology• A survey was sent to subscribers of specialized industrial publications. This study was conducted by IFS• Sample size: 200. North America• Respondents were screened for and Mint Jutras, an independent involvement in enterprise software research-based decisions and for company size of consulting firm that specializes in greater than $100 million in annual analyzing the revenue. business impact of enterprise applications.
  4. 4. Methodology• Frequencies on the data were run to reflect the differing technological approaches taken This study was by some specific types of companies, conducted by IFS including: North America – Companies engaged in engineer to and Mint Jutras, order manufacturing. an independent research-based – Companies delivering projects as an consulting firm engineering, procurement, and that specializes in construction contractor. analyzing the – Those involved in batch process, which business impact would cause them to be involved of enterprise heavily in enterprise asset applications. management of process manufacturing plants and equipment.
  5. 5. Major Areas Explored– How complex is the modern Applications such as: manufacturing and industrial  Enterprise Resource environment? Planning (ERP)  Project and portfolio– How does this complexity affect the Mgt (PPM) number and type of enterprise  Customer Relationship software applications respondents Mgt (CRM)  Enterprise Asset use to run their business? Management (EAM)– How can industrial companies  Computerized Maint. Mgt System (CMMS) better manage this complexity?  Supply Chain Mgt (SCM)
  6. 6. Key Findings– Most manufacturers must deal with managing a variety of styles of manufacturing including multiple flavors of “to order.”– Batch process manufacturers, engineer to order manufacturers and engineering, procurement and construction contractors all are involved in multiple other business processes.– This creates a need for multiple enterprise applications; companies average 3.24 different types of applications - and as many as 7.– The better an enterprise software environment facilitates project management in an integrated way, the better it meets a variety of complex needs.
  7. 7. Why Is This Important– The promise of an enterprise solution like ERP is to pull the entirety of key enterprise data and processes into a single application. This yields: • Enhanced visibility for corporate management • Improved access to operational data for middle market managers. • A consistent, streamlined work environment for individual contributors. • Increased diversification and complexity causes the business’ needs to grow beyond the capacity of their existing systems, and they augment them with additional applications.– This threatens to defeat the purpose of the enterprise system.
  8. 8. Company Size (Annual Revenue) $100M - $149.9M, 16% $2.5 Billion or more, 29% $150M - $249.9M, 10% $250M - $1B - $499.9M, 20% $2.49B, 12% $500M - $999.9M, 13%
  9. 9. Manufacturing Styles Make to Order 66% Make to Stock 48% Batch Process 36% Engineer to Order 36% Custom Manufacturing 32% Configure to Order 31% Continuous Process 27% Design Fabricate Install 15%Engineer Procure Construct 12% 0% 10% 20% 30% 40% 50% 60% 70% Respondents were allowed to select all that apply. On average each respondent selected 3.26 different styles, adding to the complexity of the environments.
  10. 10. ETO is Typically Combined with Other Styles - Adding More Complexity Engineer to Order 100% Make to Order 79% Make to Stock 50% Configure to Order 43%Custom Manufacturing 33%Design Fabricate Install 21% Continuous Process 14% 0% 20% 40% 60% 80% 100%
  11. 11. ETO is Typically Combined with Other Styles - Adding More Complexity• Engineer to Order manufacturers are really multi-mode manufacturers as they combine ETO with other styles as well.• This increases complexity.• Among participants reporting involvement in engineer to order: – 79% also do make to order – 50% also have some element of make to stock – 43% configure to order. – 33% are doing some level of custom manufacturing. Custom manufacturing differs from ETO in that the specification or design is generally provided to a custom manufacturer whereas an ETO manufacturer typically needs to design a product or system to meet specific deliverables.
  12. 12. Batch Process is Typically Combined with Other Styles - Adding More Complexity Batch Process 100% Make to Order 71% Make to Stock 45% Some of these stylesCustom Manufacturing 32% require VERY different Engineer to Order 32% approaches and types of enterprise software Continuous Process 31% functionality. Configure to Order 29% Batch ProcessDesign Fabricate Install 13% 0% 20% 40% 60% 80% 100% 120%
  13. 13. Batch Process is Typically Combined with Other Styles - Adding More Complexity• Batch process is normally associated with a more repetitive manufacturing environment. This data, however, suggests that in the modern batch process environment, make to stock is not the default method.• Among batch process manufacturers, 71% are making to order – and this was the most common business model associated with batch process.• Other associated business models include make to stock, custom manufacturing, and even engineer to order.• Engineer to order can be a factor for process manufacturers involved in: – Adhesives – Explosives/Energetics – Chemicals – Lubricants
  14. 14. EPC Involves Multiple Other Styles - Adding More ComplexityEngineer Procure Construct 100% Engineer to Order 70% Make to Order 53% Custom Manufacturing 50% Configure to Order 50% Design Fabricate Install 47% Make to Stock 43% Engineer Continuous Process 40% Procure Batch Process 37% Construct 0% 20% 40% 60% 80% 100% Multiple business models are a necessary part of EPC. Process was a surprise here, but perhaps shouldn’t be given large diversified industries.
  15. 15. EPC Involves Multiple Other Styles - Adding More Complexity• Engineering, procurement and construction is the most complex business model among those dealt with in this study. – Engineering drives design data and product data management requirements. – Construction drives project management and subcontract management requirements. – Fabrication or manufacturing requires standard manufacturing and shop floor management functionality.• Companies doing engineering, procurement, construction are using the largest number of different types of applications. Multiple discrete manufacturing models are a necessary part of EPC. Batch process may be listed due to the diversified nature of these companies.
  16. 16. Processes Important to Your Business Repetitive or continuous process MFG 67% Lean manufacturing 58% Maintenance of capital assets 52% Mgt of outside manufacturing 49%Mgt of one-off projects (engineering or fabrication) 47% Planning or project mgt for new capital assets 45% Vendor-managed inventory 35% Recipe management 33% Field Service Management 30% Aftermarket service or support 30% Satisfying defense MFG business reqts 16% 0% 25% 50% 75%
  17. 17. Important Business Processes• It is remarkable how many different processes there are and the degree to which they overlap. – Repetitive manufacturing. – Continuous processes. – Lean manufacturing. Lean is often associated with inventory reduction in repetitive discrete manufacturing environments, but this data reminds us it is also relevant to process manufacturing and to project-driven discrete. – Process manufacturing. – Asset management is particularly important in a process environment, because the machines are delivering as much or more value than people. Intelligent maintenance of those capital assets on an ongoing basis is critical.
  18. 18. Complicating Factors• Virtually everyone today has to deal with some level of outside manufacturing, whether it is offshore, near-shore or on shore. More than half of respondents reported managing manufacturing contractors as a key process.• Field service as a discipline requires effective scheduling and management of engineers in the field. This extends the application environment into new functions including dispatch, geospatial analysis and mobile work order reporting, management of mobile inventories, etc.• Field service management, vendor managed inventory, aftermarket service or support and capital projects management all require increasing degrees of involvement with the enterprise data from outside the four walls of facility.• Defense department requirements for manufacturing tends to be extremely complex, particularly in the project reporting and control.
  19. 19. Which Processes Produce the Most Software Complexity?Number of Applications 5.1 After Market Service 7.0 Defense Department Requirements 4.0 Maintenance of capital assets 3.1 One off projects 0.0 2.0 4.0 6.0 8.0
  20. 20. Which Processes Produce the Most Software Complexity?• Several specific business processes stood out as the most complex, requiring the largest number of software applications.• Companies in these industries may need to find enterprise applications that better support their unique needs in order to: – Reduce software license and maintenance costs by cutting down on the number of different software products they run. – Eliminate duplicate data entry and non-value added work. – Eliminate data silos that prevent thorough, real time visibility of the business. – Increase the ability of different parts of the business to collaborate and work together.
  21. 21. Which Processes Produce the Most Software Complexity?• Aerospace and Defense and After Market Service are the two most demanding, followed by Asset Management and project environments like Engineer to Order and Engineering Procurement Construction. – Regulation originating with the defense department or ministries of defense requires very specialized reporting, control, and inventory segregation. – Combine this with the very complex projects that characterize the defense environment and we see why they are running on average 7 different types of applications – Companies involved with the after market service are field support, may require depot repair, customer relationship management, contract management, tools to ensure they meet specific service level agreements – plus maintenance, repair and overhaul and other functionality. That is why on average they are running 5.1 different types of applications.
  22. 22. Which Processes Produce the Most Software Complexity?• Companies involved with maintenance of capital assets also face a complex enterprise software environment, with an average of 4 types of enterprise software in place.• Companies managing one-off projects are actually using relatively few different types of applications at only 3.1. Based on the data, they are probably not using enough and they don’t have the level of control that they need given what we have found about the lack of integration between project management tools and ERP.• The kinds of applications that are in place across respondent firms range from ERP to supply chain management to manufacturing execution, computerized maintenance management systems, product lifecycle management or product data management and others.
  23. 23. Enterprise Applications in Place• ERP is the most widely used application of any in this study. At 71%, this falls within a range seen in other studies that show between 70% and 80% of manufacturers have implemented ERP. That percentage drops outside of the manufacturing space.• Because ERP solutions have grown in footprint, over time, different applications could be included as part of an ERP platform. This is generally a positive because a company running a broader footprint of ERP will not have to integrate ERP with various other applications.• In some demanding environments, however, ERP is not satisfying requirements for human capital management, project portfolio management, field service management, product data management, etc. This would force a company to implement additional software products.• Greater complexity drives the implementation of more and more enterprise software products.
  24. 24. Enterprise Applications in Place ERP 71% Suppy Chain Mgt (SCM) 40% MES 29% CMMS 29% Product Data Mgt (PDM) 27% CRM 26%Enterprise Asset Mgt (EAM) 23% Human Capital Mgt (HCM) 19%Project Portfolio Mgt (PPM) 15% Field Service Mgt (FSM) 12% All Respondents Other 7% 0% 25% 50% 75% On average companies have a total of 3.24 different enterprise application products implemented.
  25. 25. Role of Projects• Project management plays a key role in many of the different business models dealt with in this study. – Very few respondents report strong integration between systems used for project management and their enterprise systems like ERP, EAM, etc. – On the whole, greater integration between project management functions increases the degree to which an enterprise software system supports business processes. – Only 4% report that they use a module within their ERP system for project management, which would constitute the highest level of interactivity between projects and other business functions.
  26. 26. What Level of Integration?Between Project Mgt & Enterprise System of Record All Respondents40% 39% 30%30%20% 13% 14%10% 4%0% None Selective Financial Full integration Embedded as integration integration a native part of ERP
  27. 27. Project Integration Matters How well does your business software facilitate Level of Integrationthese important processes? (Rate on scale of 1 to Full or Partial Total None 5 with 1 being no support and 5 being very well embedded integration Management of repetitive manufacturing or 3.70 4.05 3.77 3.45 continuous process manufacturing Management of one-off projects like 3.31 3.81 3.51 2.84 engineering or fabrication Recipe management as used in batch 3.50 3.74 3.62 3.25 manufacturing Management of outside manufacturing 3.19 3.76 3.36 2.74 partners and suppliers Aftermarket service or support through maintenance contracts, repair, 3.26 3.59 3.53 2.70 replenishment, etc. Field Service Management 3.24 3.54 3.33 2.93 Maintenance of capital assets, i.e. 3.33 3.67 3.55 2.90 manufacturing equipment Planning or project management for new capital assets including manufacturing 3.30 3.82 3.53 2.76 facilities, refits, rebuilds, etc. Satisfying defense manufacturing business 3.33 3.63 3.57 2.75 requirements Vendor-managed inventory 3.22 3.77 3.34 2.75 Lean manufacturing 3.20 3.75 3.29 2.84
  28. 28. About IFSIFS is a public company (OMX STO: IFS) founded in 1983 thatdevelops, supplies, and implements IFS Applications™, a component-based extended ERP suite built on SOA technology.IFS focuses on agile businesses where any of four core processes arestrategic: service & asset management, manufacturing, supply chainand projects.The company has 2,000 customers and is present in more than 50countries with 2,800 employees in total.
  29. 29. Contact Information: Charles Rathmann, Analyst IFS North America