Case Study - ERP for Plastic Moulded Components Manufacturer
About the Client
The Client is into manufacturing of Plastic Moulded Components like Car Bumpers, Dashboards, Horn pad, Instrument Panels etc. At present they have more than 20 injection molding machines each having capacity greater than 250 ton. Their major processes involve injection molding and vacuum forming. The company is reputed for its High Quality and on-time deliveries. They have multiple factories in Northern part of India. They are amongst the leading suppliers of Plastic Moulded components to Suzuki Motors in India. They also supply to other major Automobile and White goods companies in India.
Implementation Objectives
The company wanted to have an ERP which can co-relate the customer schedule with its production planning and inventory so that problems of manual planning can get resolved. They wanted to bring in automation and integration in its daily tasks in structured and disciplined manner e.g. Production as per customer daily schedule, controlling the raw material stock as per production planning, generating invoices as per DI of customer etc. Some of the crucial reports which the company wanted were product costing, daily stock, daily rejections, mould break down, customer outstanding, stock valuation etc They were earlier using a small time ERP which was not able to provide the information they wanted for proactive management and controlling operations.
Functionalities
The company opted mostly for standard business process available in ebizframe. Some customizations were done to suit client’s business operations specifically in Order Scheduling and Production Planning areas. Some of the specific functionalities in use are:
- Interfacing with Suzuki’s e-nagare extranet for Order delivery schedules, Actual Deliveries, Payment reconciliation
- SupplierCARD (Automatic entry of Supplier’s shipment details using Bar Code Scanning). Bar code generated by Suppliers from Company’s own Extranet)
- Product Costing
- Generation of Mould and Cavity requirement as per plant capacity
- Shortages management
- Plan v/s Actual Production
- Mould Breakdowns
- Productivity reports
- Rejection Reports
- WIP
- State Specific VAT Reports
- Excise Tax Reports
Benefits Derived
After implementation of ebizframe ERP, the machine and mould planning, raw material requirement planning has become very systematic and easy.
Planning department has access to actual schedule of customer on daily basis. Machines and mould position is available online. With availability of accurate information, the time taken for planning has reduced to great extent.
As the Production has full information of product, moulds and the shifts, it has eased the process of machine loading.
The Sales department has hands-on information about stock. ESS has also interfaced the ERP with the Supply chain management systems of the Automobile Manufacturers (Like Suzuki’s e-nagare) which helps the Company to do automatic download of Schedules, upload of deliveries and automatic reconciliation of payments.
