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ERPPPT
- 1. ERP ? ( FoundrySpecific ) 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 ERPCharacteristics 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.
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- 4. ERP : facilitatesinformation 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 Focuson “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 MonitoringControl 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, deployand 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 LeanManufacturing 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 ImplementingERP ( & 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 inERP 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 IDEALERP should be ?
- 12. Highly Scalable ERP Corporate Legal Entity1 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 DataWarehouse 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 CashForecasting 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 ofcredit •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 Forwardfor Approval Forward for Review Return PO Review PO Approval Workflow Based Approvals PO Entry
- 18. Integrated Business Processfor 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
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- 23. Operational Reports Finance CashOn 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 wiseMaterial 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 ProductionPlan 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 EmployeeProvident 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 ERPArchitecture 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.
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- 33. Capable to captureProduction 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 costingprocess wise to be fixed here) Process Costing
- 35. To Summarize onIdeal 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 onIdeal 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 & StrategyFormulation Awareness Programme 1 An Ideal Implementation 2 3 4 5 6 7
- 38. ERP Implementation Tracker AB 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 ManagementPerspective … What should they get ?
- 41. Management Portal :Dashboard
- 42. Management Portal :Dashboard
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- 46. Accounting General Ledger Master Production Schedule Material Requirement PlanningBillof 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 viaERP allows the machine & human resources to : * Systematically exchange intelligence * Respond with speed & superior performance which will help create "smart foundries”
- 48. On his Dreamof 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 Foundrymencan say, We will.
- 50. Thank you Presented by: Appu Director– Customer Relationship Roadmap IT Solutions Private Limited Pondicherry, India