| Case Study 1 |
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Client - Fabrication of dumper body, made to
order.
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| Case Study 2 |
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Client - Foundry business, Manufacturing
castings to order.
Read More |
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| Case Study 3 |
Client - Manufacturing high tech precision
component for two wheeler
and four
wheeler car industry.
Read More |
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| Case Study 1 |
| Client - Fabrication of
dumper body, made to order |
| Major pain points: |
- High manufacturing lead time.
- Inventory levels not balanced leading
to excess and short inventory.
- Several manual registers and recording
methodology.
- Several non value adding processes
affecting costs and creating waste.
- Manual compilation of reports and MIS
affecting accuracy and completeness.
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| Results achieved by implementing
ValGn-ES |
- Automated MRP based on sale orders and
delivery schedules given by customers
- Bill of material defined for all
products.
- Better planning lead to better
availability of material and also better
purchase price for raw materials.
- Process and data integration lead to
better inter-process control resulting
in purchase optimization, inventory
optimization. Wasteful exercises like
manual registers writing, manual
verification of certain details are
eliminated by pushing the business rules
into the software.
- Automatic generation of documents like
Purchase Order, Invoice etc. leading to
time saving and accuracy.
- Generation of MIS reports using real
time data enabling the management take
the right decision at the right time for
running the business more profitably.
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| Case Study 2 |
| Client - Foundry
business, Manufacturing castings to order |
| Major pain points: |
- No control on material purchase.
- No control on rates.
- Several purchases without approvals.
- No validation of material inward with
purchase orders leading to excess/short
inventories.
- Absence of proper sub-contract support
system leading to confusion relating to
the materials lying at the
sub-contractors™ premises and there by
non-compliance on statutory regulations.
|
| Results achieved by implementing
ValGn-ES |
- All purchases are routed thru a
purchase request system leading to
better control on purchases.
- Work flow hierarchy defined in the
system and approval through system only.
Multiple levels of approval
configurable. No purchase goes without
the knowledge of the responsible
persons.
- Centralized master for purchase rates
and approved suppliers. Leading to
control on rates. Also leading to
purchase only from approved suppliers.
- Validation of inward purchase quantity
with purchase orders leading to supply
as per orders only.
- System for GRN preparation and
inspection leading to better quality
control and update of stock only for the
quality approved supplies.
- Automatic rejection note generation
system leading to better control on
rejected material and sending back to
supplier.
- Sub-contract module enabled the user to
generate the required statutory
documents through system enabling the
inventory of materials at the
sub-contractor™s place a reality.
- Also the MIS and other reports enabled
the client to comply with excise
regulations.
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| Case Study 3 |
| Client - Manufacturing
high tech precision component for two wheeler
and four wheeler car industry. |
| Major pain points: |
- Delay in customer deliveries.
- Planning hurdles due to non
availability of required information.
- Absence of planning in sub-contract
job.
|
| Results achieved by implementing
ValGn-ES |
- Able to plan requirements for firm and
tentative requirements.
- Flexible planning horizon up to a
maximum of 52 weeks with firm and
tentative periods for visibility ahead.
- Facility to revise the plan once in a
fortnight enabling changes to the plan
based on markets demands.
- Automated MRP using the bill of
material. This resulted in procurement
of matched sets of components rather
than too much of certain components and
not enough of other components thus
ensuring smooth manufacturing and no
waiting for want materials due to bad
planning. With fewer part shortages
manufacturing orders are be processed to
completion faster. Has also resulted in
reduced Work in Process inventories.
- Since sale order is the base for
planning the focus is on delivery.
- Configurable parameters like
procurement lead time, manufacturing
lead time and logistics lead time enable
the client to factor al these parameters
into the planning, leading to a very
near realistic plan. This ensures
manufacturing to meet the delivery
requirement as per customer demand.
- Also the ability to maintain alternate
bill of material, alternate routing
gives the client option of alternate raw
material and alternate processing in
case there is change in the plan.
- Work in process tracking at every stage
of production leading to better control
on WIP stock.
- Sub-contractor™s support module lead to
better planning of sub-contracted
material requirement.
- Also the statutory compliances on
sub-contracting are met since the
support provides for monitoring and
generating reports.
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