1. ERP ?
( Foundry Specific )
An integrated business automation application
that foundrymen can use to collect, store,
manage and analyse data from business
operations for a sustained profitable growth.
ERP = Connected Enterprise

2. An Ideal ERP Characteristics for Foundrymen
• An integrated system for “Smart Foundries”.
• Operates real time & support industry “best
practices”.
• Uses a “common database” to supports all
applications including Android, iOS.
• System with elaborate application & data
integration.

3. Why ERP ?

4. ERP : facilitates information flow between business functions
Customer
Sales Order
Procurement
Production &
Costing
Distribution
Accounting &
FinanceHR &
Payroll
CorporatePerformance &Governance
Customer
Feedback
Customer
Service
Business
Intelligence
e-commerce
and others…
Enterprise Asset
Management
1 2
3
4
5
6
7
8
9

5. Benefits
• Help Focus on “Excellence” in every
department.
• Avoids Duplication of Entries-Save Man Hours.
• Gives an EDGE over competition by focusing
on productivity, efficiency & performance.
• Provides transparency & Real-time data to
take right business decisions at right time.
• Replaces diverse systems with uniform &
integrated workflow.

6. Benefits
• Helps Monitoring Control on Pattern, Die &
Tool Life utilization.
• Notification on Equipment, plan preventive
Maintenance schedule to avoid Breakdown.
• Helps to focus on Repair History,
Maintenance cost, Maximizing Asset
utilization & Productivity.

7. Benefits
• Design, deploy and optimize manufacturing
process to check on costing.
• Helps focus on achieving quality benchmarks
for international standards like ISO, APQP,
SPA, MSA, 8D, 5S Audit etc.
• Improve forecasting, using historical data to
plan business better.
• Accurately Control Financials including cash
flow & fund flow (incl. Budget Vs Actual,
analysis).

8. Benefits
• Support Lean Manufacturing for “Releasing
Hidden Capacity” & improve operational
efficiency
• Support the manufacturing process with
“book tallied” costing.
• Automated Machinery output should be in
sync with ERP.
• Energy efficiency should be monitored &
reported via ERP to management.

9. Challenges in Implementing ERP
( & how to overcome )
Customization of Unique demands
(Selecting the right ERP Vendor)
Re-engineering business processes
(Meticulous Planning & Motivated Team)
“Switching cost” from existing application
(Calculating ROI, Few Indian ERPs work on 12 month ROI)
Overcoming internal resistance
(Motivated Team & Awareness Program )
Training manpower while continuing business
(Extensive Support from ERP Vendor)

10. Modern trends in ERP Applications
• Flexible ERP which can use iOS, Android @
application level.
• Web-enabled ERP - cloud services for small
enterprise.
• Social ERP Ex: Tweet-for-a-taxi, connecting
FB comments to customer feedback.

11. How an IDEAL ERP should be ?

12. Highly Scalable ERP
Corporate
Legal
Entity 1
Legal
Entity 2
Legal
Entity n
Unit 1(Manufacturing)
Warehouse
Unit 2 (Distribution) Unit n (Manufacturing
/Distribution)
Procurement/Finance/Sales Work Center/Process/
Production Line
W1
W2
Wn Purchase Sales Finance Work
Center 1
Work
Center n
Work
Center n

13. Web Enabled
Internet / VPN /
RF / Lease line
Corporate Office
Application
Server
Database
Server
Analytical
Database
Firewall
Data Center
Router
Manufacturing Unit 1,2…n
Branch Office 1,2..n
Employee
Portal
Supplier
Portal
Customer
Portal
Remote
Users
Executive
Management System
Dashboard/KPI’s

14. Web User
Application
User
Web
Database
server
Operation
DB
Flat Files
Data Warehouse
Meta Data
Summary Data
Purchase
Analysis
Reporting
Mining
Sales
Anywhere Office (Cloud Support)
Web User
Application
User
Application
Server
Operation
DB

15. Purchase Requests
Cash Budget
Cash Forecasting
Purchase Order
Purchase Receipts
Accounts Payable
Sales Order
Opportunities
Accounts
Receivable
Payroll
Inflow
Manual Entries
Manual Entries
Outflow
Cash Flow
Daily
Weekly
Monthly

16. Paperless Office
•Letter of credit
•Bill of Lading
•C&F Document
•Export Doc.
•Rate Contract
• Sup. Tin Copy & Any
other doc.
•Letter of credit
•Bill of Lading
•C&F Document
•Export Doc.
•Rate Contract
• Sup. Tin Copy & Any
other doc.

17. Email
Return
Reject
Buyer
Supplier
End
(Rejected)
End
(Approved)
Sample Purchase Order
Reject
Notification
Notification
Forward for
Approval
Forward for
Review
Return
PO
Review
PO
Approval
Workflow Based Approvals
PO Entry

18. Integrated Business Process for foundry
Raw Materials: sand,
bentonite, coal-dust,
chemical binding
systems
Charge materials:
Pig-iron, scrap and
Ferro alloys
Charge Preparation
Melting in electric
Induction furnace or
a cupola
Inspection and
Delivery
Finishing
Operation
Sand blasting
grinding removal of
Gates and feeders
Shake out
Pouring
Core setting and
Mould closing
Green sand
Moulding
Core
Making
Green sand mulling
core sand mixing

19. Demand Management
MRP
Prod. Plan & Execution
Gate Entry
GRN
General
Ledger
Journals
Picking &
Shipping
Invoices
AR
Documents
CRM
AR Receipts
Planned Order Release
Purchase Request Subcontract Request
Stocks
QC
Outside Inside
Quality Inspection
Inside /
Outside
Loop Process 1..n
Origin from
Production
RM/BO Stores Rejection WH
Proc.Cmp ltn. Record
Is Last
Process
Yes
No
Subassy/FG Receipts
FG Stock
Yes
Purchase Order Subcontract Order
Accepted/
Rejected
Bill Booking
Payment
Accepted Rejected
Customer Schedule
Integrated Business Process for foundry

20. Operational Reports

21. MIS Reports

22. Statutory Reports

23. Operational Reports
Finance
 Cash On Hand
 Cash at Bank
 Stock as on Date
 Pending Payments as on Date
 Pending Receivables as on Date
 Budget Vs Actual as on Date
 P & L, Income Statement as on Date
 Cash & Fund Flow
Purchase
 Pending Orders
 Pending Materials Followup
 Quotation and Price Finalization
 Price Fluctuation Monitoring
 Vendor Rating
 Payment Followup
Sales
 Pending Orders Due
 Schedule Vs Dispatch
Inventory
 Stock on Hand
 Pending Material Issue
 Stock Re-order Level
 Shelf Life item expiry
 GRN Day Book

24. Shop Floor Reports
Productivity
 Productivity - Daily (Actual – Qty)
- Monthly (Actual – Qty)
 Productivity Report Daily / Shift Wise
 Productivity B/A Idle Hours - Daily
 Productivity Before Idle Time - Daily
After Idle Time – Daily
Costing
 Cost Sheet - Summary
 Cost Sheet – Production Order
 Process wise Cost Element Details
 Cost Sheet Details
 Cost Sheet – Process wise
Details
 Material Shortage Summary
 Production Details – Processwise
 Production Yield % Details
 Production Process Details – Datewise
Others
 Resource Usage Details
 Idle Hours - Monthly
 Idle Hours – Daily
 Shift wise Furnace Log
 Daily Tonnage Production
 Plan Vs Actual
 Daily Production Rejection

25. MIS Reports
General Ledger
 Yearly Budget Vs Actual Analysis
 Monthly Budget Vs Actual Analysis
 Operating Expenses Report
 Comparative P & L and Balance Sheet
 Monthly Profit & Loss
 Ratio Analysis
Account Payable
 AP - Aging Analysis (INR)
 AP - Aging Analysis (FC)
 Discount Analysis
 Payable Analysis
 Letter of Credit - Issued List
 Bank Guarantee Receipts List
Account Receivable
 AR Aging Analysis - INR
- FC
 Receivable Analysis
 Discount Report
 Interest Report
 Letter of Credit Receipts List
 Bank Guarantee - Issued List
 Payment Analysis
Cash Management
 Collection Analysis – 1.Areawise
2.Territorywise
3.Subterritorywise
4. Countrywise

26. Cash Management
 Cash & Bank Balances Status
 Cash Forecasting Analysis - Daily
- Weekly
- Monthly
 Cash Forecasting Vs Actual Analysis
- Daily
- Weekly
-Monthly
Fixed Asset
 Fixed Assets Summary
 Fixed Assets Depreciation Summary
Purchasing & Subcontracting
 Monthly Purchase Analysis -Supplierwise
- Productwise
-Buyerwise
- Classwise
 Yearly Purchase Summary
 Yearly Purchase Value Difference Currency
 Yearly Purchase - Unitwise
- Sub Groupwise
- Sub classwise
 Monthly Purchase Statement – MIS
 Purchase Control Chart
 Monthly Purchase Statement (Supplier
Wise)
MIS Reports

27. Inventory
 Department wise Material Consumption
 Monthly Raw Material Consumption
 Monthly Packing Material Consumption
 Monthly Consumables Consumption
 Inventory Aging Analysis
(Fast Moving/Slow Moving)
 Stock As on Date Analysis
 Stock Summary By Warehouse
 Stock Summary By ABC Class
Quality
 Monthly Purchase Rejection (PPM) –
By Supplier, Item
 Monthly Subcontract Rejection(PPM)-
By Supplier,Item, Process
 Monthly Shop Floor Rejection (PPM) -
Item, Process, Machine
 PPM Target Vs Actual
 Open NCR Report
 Process Capability Study Analysis
 Pareto Analysis
 Gauge Calibration Analysis
 Supplier Audit Analysis
MIS Reports

28. Shop Floor
 Production Plan Vs Actual -Monthly
- Weekly
- Daily
 Idle Time Analysis
 Productivity Analysis
 Utilization Rate Analysis
 Efficiency Analysis
Sales Order
Sales Order Booking Analysis
- Areawise
- Territory Wise
- Sub-Territory Wise
- Customer wise
- Salesperson wise
- Product wise
 Sales Analysis - Areawise
- Territory Wise
- Sub-Territory Wise
Sales Return Analysis - Areawise
- Territory Wise
- Sub-Territory Wise
- Customerwise
- Salespersonwise
- Productwise
Net Sales Analysis - Areawise
- Territory Wise
- Sub-Territory Wise
- Customer wise
- Salesperson wise
- Product wise
MIS Reports

29. Sales Order
Profit Analysis - Areawise
- Territory Wise
- Sub-Territory Wise
- Customerwise
- Salespersonwise
- Productwise
Despatch Plan Vs Actual Analysis
(Ontime, Late, Early)
Production Vs Dispatch Analysis
Human Resources
Monthly Headcount Report
Salary Cost Analysis-Departmentwise
MIS Reports
CRM
 Enquiry’s Analysis
 Feasibility & Regret Analysis
 Pending Quotation
 Order Lost Analysis
 Area, Territory, Segment Wise Market
Share Analysis
Marketing
 Opportunities List
 Quotations List
 Open APQP Projects List
Customer Support
 Customer Complaints Analysis

30. Statutory Reports
 Employee Provident Fund Challan
 Employee PF Yearly Contribution
 PF Form 12 A
 PF Form 6 A
 CPF Recovery Statement
 PF - Form 5
 PF - Form 10
 ESI Challan A/C No. 1
 ESI Act Form No. 7
 ESI - Form 6
 Form TDS 16
 TDS Tax Challan |ITNS281
 Professional Tax
 Factory Employee Wage Slip
 Form 9 (Revised)
 Leave Register Form XVI
 Muster Roll
 TDS Tax Challan – ITNS281
ESI
TDS  Annexure I
 Annexure IA
 Annexure II
 Annexure III
 Annexure IV - Export
 Annexure IV – Import
 Form I
 RG23A Part I
 RG23A Part II
 RG23C Part I
 Part II
 RG1
 Service Tax
 Annexure 19
 Part I, II ,III, IV, V
Annexure 63
 ER -1
PF
Others
Professional Tax
Excise
Sales Tax

31. An Ideal ERP Architecture
ecture
Financial
Accounts
Payable
Accounts
Receivable
Cash
Management
Taxation Fixed Assets
Sales & Distribution Sales
Order
Gate Entry
Management
Inventory
Control
Transportation
Management
Subcontract
Quality
Control
SPC Auditing MSA
Planning &
Manufacturing
Master
Production
Schedule
Material
Requirement
Planning
Bill of Materials
Shop Floor
Manufacturing
Schedule
Demand
Management
Cost
Management
Operational Job Order ContractBatch ABC
HR & Payroll
Recruiting Portfolio Orientation Leave Mgmt.Training & Dev.
TicketingMedical Business Trip
Appraisal
Self Services PayrollGovt. Relation
Marketing
Lead Opportunity Quotation
Budgeting
Flexible Rolling
Other Modules Project
Management
Fleet
Management
Cane
Management
Customer
Support
General
Ledger
Purchase
Order
Inspection
Routing
Manufacturing
Resources
Planning(MRP-II)
Process
Planning
Loan Mgmt.
Campaign
Static
Engineering
Field
Service
Workflow
Mgt.
Activity Mgt. Notification MIS
Reporting
Plant
Maintenance
C
R
M
AMC/
Warranty Mgt.
Service WO
Mgt.

32. Inventory Management

33. Capable to capture Production Process
Process
Melting and Furnace Log Details
Mould and Core Details
Manual and Auto Poring
Capturing Runner & Raisers, Spillage and Slag.
Shot Blasting
Fettling and Fettling Consumption
Machining Operations

34. (screenshot showing costing process
wise to be fixed here)
Process Costing

35. To Summarize on Ideal ERP
• Scalable from 5 to 500 users (unlimited users).
• Swift & committed implementation.
• Reliability on Build, Implementation & back-up
Support.
• Focus on Best Practices for Strengthening the
Foundry Industry.
• Enhancing Managerial Effectiveness by
Connectivity to “plant floor information”.

36. To Summarize on Ideal ERP
• Support multiple Indian Tax Laws with “one
touch info”.
• Provision for “Enterprise centric customization”
& user friendly application.
• Customizable MIS Reports : as needed by senior
management.
• Should support “book-tallied” costing.

37. Preliminary Analysis &
Strategy Formulation
Awareness
Programme
1
An Ideal Implementation
2
3
4
5
6
7

38. ERP Implementation Tracker
A B C D E F G H I J K L
1
2
3
4
5
6
7
8
9
Date Dept. Task Task Details Responsibility Plan Start
Due
Plan End
Due
Actual Start
Date
Actual
End Date
Status Comments Corrective
action
14-Jul-14 All Project
Kick-off
Roadmap ERP-Alphacraft
Project Kick-off Meeting Both
14-Jul-14 14-Jul-14 14-Jul-14 15-Jul-14
Overview
Completed
on 15
14-Jul-14
14-Jul-14
14-Jul-14
14-Jul-14
15-Jul-14
All
All
All
All
Mark
eting
General
General
General
General
Process Study
Implement Project Tracker
Revised Implementation Plan
Roadmap
Roadmap
Roadmap
Roadmap
Roadmap
14-Jul-14
15-Jul-14
14-Jul-14
14-Jul-14
14-Jul-14 15-Jul-14
15-Jul-14
14-Jul-14 14-Jul-14
14-Jul-14
15-Jul-14 15-Jul-14
14-Jul-14
14-Jul-14
15-Jul-14
Standard ASIS Study
Document
Standard Flow Chart
Marketing and Sales
Process Study
15-Jul-14 15-Jul-14
14-Jul-14 14-Jul-14
PROJECT TRACKER

39. At What cost ?
Should be a comprehensive end-to-end
business solution at :
Ideal investment
(ROI 12 months)

40. ERP !
From Management Perspective …
What should they get ?

41. Management Portal : Dashboard

42. Management Portal : Dashboard

44. Order Booking

45. ACIDULATION
Process
Management Portal : Dashboard

46. Accounting General Ledger
Master
Production
Schedule
Material
Requirement
PlanningBill of
Materials
Shop Floor
Manufacturing
Schedule
Routing
Manufacturing
Resources
Planning(MRP-II)
Demand
Management
Purchase
Order
Sales
Order
Planning
Recruiting
Portfolio
Orientation
Loan Mgmt.
Leave Mgmt.
Training & Dev.
Ticketing
Medical.
Business Trip Appraisal Self Services
Process
Batch
ABC
Accounts
Receivable
Accounts
Payable
Cash
Management
Taxation
Fixed Assets
Marketing
Customer
Support
Engineering
ToolRoom
Management
PlantMaintenance
Budgeting
Static
Flexible
Rolling
HR Intelligence Payroll
Inventory
Control
Workflow Management Activity Management Business Intelligence
An Idel ERP Architecture
Govt. Relation
Transportation
Management
Notifications
SMS , Email & Pop-Ups
Subcontract
Finance
SPA
Inspection
Auditing
MSA
QualityControl
CostManagement
HR&Payroll
Planning&
Manufacture
CRM(Pre&Post
sales)
Sales&Distribution

47. Business Integration via ERP allows the machine &
human resources to :
* Systematically exchange intelligence
* Respond with speed & superior
performance which will help create
"smart foundries”

48. On his Dream of 10% + growth in Indian
manufacturing sector, on a sustained basis
Our Prime Minister requested International Industry
Leaders to :
Come, Make in India

49. And we Foundrymen can say,
We will.

50. Thank you
Presented by:
Appu
Director – Customer Relationship
Roadmap IT Solutions Private Limited
Pondicherry, India