Take Back Manufacturing

Transcription

1 Take Back Manufacturing Computer Integrated Manufacturing ( CIM ) ERP the long journey where we have been and where are we going?

2 Genius Solutions: the Company In business for over 20 years Origins - Industrial Engineering, ISO and Best Practices consulting Since the late 90 s - Focus on ERP Software development, deployment and ongoing support Development Partner of Sage, Microsoft and SolidWorks

3 ERP Defined Enterprise resource planning (ERP) systems integrate internal and external management information across an entire organization, embracing finance/accounting, manufacturing, sales and service, customer relationship management, etc. ERP systems automate this activity with an integrated software application. Their purpose is to facilitate the flow of information between all business functions inside the boundaries of the organization and manage the connections to outside stakeholders. [1] ERP systems can run on a variety of computer hardware and network configurations, typically employing a database as a repository for information. [2]

4 The History of ERP MRP ( Material Requirements Planning ) In 1964, Joseph Orlicky as a response to the TOYOTA Manufacturing Program, developed Material Requirements Planning MRP II( Material Resource Planning ) In 1983 Oliver Wight developed MRP into manufacturing resource planning (MRP II). ERP ( Enterprise Resource Planning ) In 1990 Gartner Group first employed the acronym ERP [3] as an extension of material requirements planning (MRP), later manufacturing resource planning [4][5] and computer-integrated manufacturing. Without supplanting these terms, ERP came to represent a larger whole, reflecting the evolution of application integration beyond manufacturing. [6

5 ERP Where have we been Then Big, Expensive, Complex systems used by large manufacturers Generally Purchased by accounting and IT Requiring a lot of Feeding by many departments Requiring a lot of internal IT resources A long, expensive and risky implementation Generally designed for Make to Stock environments

6 ERP Then to Now

7 ERP Then to Now

8 ERP Then to Now Factors like Offshoring of Mass produced goods ETO / MTO Manufacturing still done in NA Outsourcing of components to suppliers The downturn creating new entrepreneurs often engineers

9 Now ERP Where are we now? Have created new ERP Smaller / less expensive, easy to use systems Purchased for a specific purpose Leaning the process Improved Costing CAD Integration Etc Requiring no internal IT A shorter more focused, less expensive and risky implementation Designed for Make to Order / Engineer to Order Because of the high engineering component involved integration between Design and Operations is critical

10 Process flow in 2 different environments: Mass Production Design is completed before order entry Production is often done for stock Purchasing raw material and components based on MRP Custom Manufacturing Design is completed after order entry More resources required for design and Order Entry Purchasing is not automated Lead time is longer Desired situation for Manufacturing Design can proceed using information from Order Entry Purchasing can be done quickly using info from OE and CAD Production has less pressure to achieve it s goals Lead time is shorter!

11 From Design to Manufacturing Product Design & CAD Manufacturing Process Design BOM & IC Execution and Operations ERP

12 Learning something from LEAN: We need to decrease the «waste factors»... Design Production Purchasing To decrease lead time, we have to remove the «slack» in each department but more-so between the department!

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16 ERP Where we were Then Running Reports that we hope someone reads

17 ERP Where are we now? Managing by exception With Dashboards

18 And Alerts sometimes on Mobile Devices An alert has been detected! GTA DATA Inventory alerts Top 10 Customers Late Jobs Late PO Receipts Programmable

19 ERP Where is it going? 5 years SaaS Cloud Computing Client Server On Premise Hosted Software as a Service ( SaaS ) Rent vs Buy Something that will not change is the importance of a good implementation Proven Process Well Defined Scope no scope creep Open to new improved processes Working together instead of departmentally

20 ERP Where is it going? 5 10 years Social Media Why enter contacts in ERP More integration between ERP & Social Media How do Manufacturers market their products Inbound vs Outbound Drive to your website Social Networks Linked In Facebook Twitter Google + So.cl ( social ) Microsoft

21 ERP Where are we now? Benefits of ERP Monitor and Improve Quality Know true profitablity by Job, by product, by customer Meet Delivery dates improve customer service Improve Purchasing buy just in time not just in case Improve Sharing of information between departments Readily Accessible, better data to make decisions Improve Productivity In the entire Business not just the shop floor Lean processes do more with less

22 Thank You!

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24 Genius Manufacturing NG Without a doubt, this is where the true value of Genius Manufacturing lies, in its ability to accommodate our changing business needs and conditions through both the lean years and growth periods, without missing a step, (Marketing Director, Motrec ) Our customer base covers a diverse range of SMB custom, MTO, ETO and discrete manufacturers with solutions for: Industrial Machinery Transportation & specialty vehicles Electrical equipment Automation and control Electronics and high tech Automotive Aerospace and defense Fabricated Metal Products Genius Manufacturing NG is designed for the unique requirements of small to midsize make-to-order, engineer-to-order, custom and discrete manufacturers. With our deep roots in process improvement and workflow optimization woven throughout, Genius Manufacturing software maximizes out-of-the-box value and return. Genius Integrates with Microsoft Dynamics GP, Sage Accpac, Sage Pro ERP, Simply Accounting and Fortsum Acomba. Genius is a robust management system capable of handling a diverse range and scale of manufacturing environments. Works with Leading Accounting Packages -- Genius Manufacturing NG extends the functionality of the financial packages with manufacturing-specific modules and processes. This allows for a comprehensive, cost effective and user friendly manufacturing system while maintaining an extensible and comprehensive platform. Manufacturing End to End Integration -- Genius Manufacturing connects your engineering, manufacturing, inventory, procurement and sales information enabling business transaction processing in real-time and accurate and timely integration with the systems that drive your business. This integrated view of production enables managers from across the enterprise; e.g. purchasing, shop floor, sales and inventory control, to launch initiatives... to perform updates... to communicate activity across the enterprise. Estimating and Quoting -- You have real-time information on inventory and access to all the documents related to the project or job: 3D drawings, PDF files, sketches etc. In an ETO, MTO or custom environment, you can create new products with the product configurator, the estimating module or the Excel Estimating module. Follow-up and track quotes. Measure your success rate by territory, customer group, product family, and track won/lost. Excel Estimating -- Manufacturers have diverse processes for estimating. Microsoft Excel is widely used. These spreadsheets can contain a knowledge base, background calculations and formulas developed and tweaked over time. With our Excel Estimating interface you can leverage and maintain your Excel tools. When completed in Excel, the information flows into Genius with costs, estimated details and creates the Bill of Manufacturing for the finished product. With this methodology you can maintain the flexibility of Excel yet flow through your ERP system such that all the data flows through the rest of your business system.

25 ÉTUDE DE CAS GILLES CUSSON & GENIUS SOLUTIONS Genius Manufacturing NG PAGE 3 Enhanced visual BOM -- This is the heart of the Genius integrated manufacturing system. Bills of Manufacturing will link estimating, planning, procurement, production, all the elements that flow through Genius Manufacturing. Our quick and simple interface allows you to build your products using a tool set purpose-built for efficiencies. These include the drag and drop capabilities. Through the visual tree everyone involved will understand, quickly and accurately, the makeup of your products, regardless of complexity. Also, as needed BOMs can be changed on-the-fly. Create multi-level BOMs to as many levels as needed. Drill-down views give rapid access to the details at each node. This module becomes the reference point for your products. Document Management -- Throughout their operations companies require information and documents such as drawings and models, specifications, compliance and inspection documents. The on-line documents management enables users to attach electronic documents within the system and add reference items to BOMs. Keep the documents where they are needed. Attach all document formats across the application, whether it is an estimate, purchase order, Bill of Manufacturing, or sales order. Centralize them all with Genius Manufacturing. Also, necessary documents can be printed as part of the work order. Production Planning: Genius delivers a broad array of capabilities and provides the flexibility demanded in custom manufacturing environments. For planning Genius offers easy-to-use yet comprehensive tools. This includes real-time feedback from the production floor with data collection. With real time information you can make the decisions and adjustments needed to keep production in line and on schedule. Your instructions and information are clearly tied to each job and work order. Whether it's manufacturing jobs, R & D or maintenance, you can carry out the jobs and follow the established plan. Procurement: Build quotations, purchase for requirements; or let Genius s MRP and forecasting determine purchases of components or raw materials. These will tie into jobs launched and inventory supplier settings. You have lead times and need timely notice for delivery of purchased raw materials and inventory components. Starting with BOMs, Genius can look out over your planning horizon to identify potential problems and bottlenecks. Inventory Control: Inventory management is crucial in controlling costs and maintaining optimum levels for production. Our advanced tools ensure that you have the right parts, at the right time and in required quantities. Avoid problems related to fluctuating inventory demands. Ensure traceability of raw materials, components as well as finished products.

26 Genius Manufacturing NG Job and Time Management Launch and execute multi-level jobs and work orders from BOMs or manage dynamically with change orders or staggered releases. Track time on jobs and projects for status and costing using timesheet functions on bar code data collection stations. Get detailed updates on all the activities and resources consumed. GTA, Genius Task Automator Automate tasks and set up alerts so you can maintain control over your most important activities and facilitate communications across the enterprise. For example, head off problems with inventory, late PO receipts, late jobs and employee load and streamline service operations. Business Intelligence and Analytics Using the Microsoft SQL Analysis Services Genius delivers Business intelligence out of the box delivering critical analytics and metrics that give visibility to the heartbeat of your business. Never before has it been this easy and inclusive to drill through and turn your data into information; all while using familiar tools such as Microsoft Excel as a tool connected directly to your database. Dashboards: Managers and owners need timely information about the business. Having the right information at the right time allows you to make good decisions. Our dashboards and alerts provide the dynamic tools to deliver updated information. Define your tolerances, limits or parameters and the system will flag situations that could create headaches. With the heads-up you can take corrective measures. GeniusWorks - Manufacturing Software for SolidWorks 3D CAD. With SolidWorks and GeniusWorks, engineering and production can share and control data to save time, reduce data entry errors, cut design and development costs, and minimize production errors. Working right inside SolidWorks, GeniusWorks bridges the gap from design and modeling to day-to-day operations. This gives you the tool set for an integrated end-to-end solution from engineering and design on through production/erp to Microsoft Dynamics GP, Sage Accpac, Simply Accounting and Fortsum Acomba financials. We are producing goods faster than ever before and have boosted production by at least 50%, (Co-owner, Elka Suspension Inc.) Web: Toll Free: sales@geniuserp.com (English) (French)

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28 Genius Manufacturing NG Without a doubt, this is where the true value of Genius Manufacturing lies, in its ability to accommodate our changing business needs and conditions through both the lean years and growth periods, without missing a step, (Marketing Director, Motrec ) Our customer base covers a diverse range of SMB custom, MTO, ETO and discrete manufacturers with solutions for: Industrial Machinery Transportation & specialty vehicles Electrical equipment Automation and control Electronics and high tech Automotive Aerospace and defense Fabricated Metal Products Genius Manufacturing NG is designed for the unique requirements of small to midsize make-to-order, engineer-to-order, custom and discrete manufacturers. With our deep roots in process improvement and workflow optimization woven throughout, Genius Manufacturing software maximizes out-of-the-box value and return. Genius Integrates with Microsoft Dynamics GP, Sage Accpac, Sage Pro ERP, Simply Accounting and Fortsum Acomba. Genius is a robust management system capable of handling a diverse range and scale of manufacturing environments. Works with Leading Accounting Packages -- Genius Manufacturing NG extends the functionality of the financial packages with manufacturing-specific modules and processes. This allows for a comprehensive, cost effective and user friendly manufacturing system while maintaining an extensible and comprehensive platform. Manufacturing End to End Integration -- Genius Manufacturing connects your engineering, manufacturing, inventory, procurement and sales information enabling business transaction processing in real-time and accurate and timely integration with the systems that drive your business. This integrated view of production enables managers from across the enterprise; e.g. purchasing, shop floor, sales and inventory control, to launch initiatives... to perform updates... to communicate activity across the enterprise. Estimating and Quoting -- You have real-time information on inventory and access to all the documents related to the project or job: 3D drawings, PDF files, sketches etc. In an ETO, MTO or custom environment, you can create new products with the product configurator, the estimating module or the Excel Estimating module. Follow-up and track quotes. Measure your success rate by territory, customer group, product family, and track won/lost. Excel Estimating -- Manufacturers have diverse processes for estimating. Microsoft Excel is widely used. These spreadsheets can contain a knowledge base, background calculations and formulas developed and tweaked over time. With our Excel Estimating interface you can leverage and maintain your Excel tools. When completed in Excel, the information flows into Genius with costs, estimated details and creates the Bill of Manufacturing for the finished product. With this methodology you can maintain the flexibility of Excel yet flow through your ERP system such that all the data flows through the rest of your business system.

29 ÉTUDE DE CAS GILLES CUSSON & GENIUS SOLUTIONS Genius Manufacturing NG PAGE 3 Enhanced visual BOM -- This is the heart of the Genius integrated manufacturing system. Bills of Manufacturing will link estimating, planning, procurement, production, all the elements that flow through Genius Manufacturing. Our quick and simple interface allows you to build your products using a tool set purpose-built for efficiencies. These include the drag and drop capabilities. Through the visual tree everyone involved will understand, quickly and accurately, the makeup of your products, regardless of complexity. Also, as needed BOMs can be changed on-the-fly. Create multi-level BOMs to as many levels as needed. Drill-down views give rapid access to the details at each node. This module becomes the reference point for your products. Document Management -- Throughout their operations companies require information and documents such as drawings and models, specifications, compliance and inspection documents. The on-line documents management enables users to attach electronic documents within the system and add reference items to BOMs. Keep the documents where they are needed. Attach all document formats across the application, whether it is an estimate, purchase order, Bill of Manufacturing, or sales order. Centralize them all with Genius Manufacturing. Also, necessary documents can be printed as part of the work order. Production Planning: Genius delivers a broad array of capabilities and provides the flexibility demanded in custom manufacturing environments. For planning Genius offers easy-to-use yet comprehensive tools. This includes real-time feedback from the production floor with data collection. With real time information you can make the decisions and adjustments needed to keep production in line and on schedule. Your instructions and information are clearly tied to each job and work order. Whether it's manufacturing jobs, R & D or maintenance, you can carry out the jobs and follow the established plan. Procurement: Build quotations, purchase for requirements; or let Genius s MRP and forecasting determine purchases of components or raw materials. These will tie into jobs launched and inventory supplier settings. You have lead times and need timely notice for delivery of purchased raw materials and inventory components. Starting with BOMs, Genius can look out over your planning horizon to identify potential problems and bottlenecks. Inventory Control: Inventory management is crucial in controlling costs and maintaining optimum levels for production. Our advanced tools ensure that you have the right parts, at the right time and in required quantities. Avoid problems related to fluctuating inventory demands. Ensure traceability of raw materials, components as well as finished products.

30 Genius Manufacturing NG Job and Time Management Launch and execute multi-level jobs and work orders from BOMs or manage dynamically with change orders or staggered releases. Track time on jobs and projects for status and costing using timesheet functions on bar code data collection stations. Get detailed updates on all the activities and resources consumed. GTA, Genius Task Automator Automate tasks and set up alerts so you can maintain control over your most important activities and facilitate communications across the enterprise. For example, head off problems with inventory, late PO receipts, late jobs and employee load and streamline service operations. Business Intelligence and Analytics Using the Microsoft SQL Analysis Services Genius delivers Business intelligence out of the box delivering critical analytics and metrics that give visibility to the heartbeat of your business. Never before has it been this easy and inclusive to drill through and turn your data into information; all while using familiar tools such as Microsoft Excel as a tool connected directly to your database. Dashboards: Managers and owners need timely information about the business. Having the right information at the right time allows you to make good decisions. Our dashboards and alerts provide the dynamic tools to deliver updated information. Define your tolerances, limits or parameters and the system will flag situations that could create headaches. With the heads-up you can take corrective measures. GeniusWorks - Manufacturing Software for SolidWorks 3D CAD. With SolidWorks and GeniusWorks, engineering and production can share and control data to save time, reduce data entry errors, cut design and development costs, and minimize production errors. Working right inside SolidWorks, GeniusWorks bridges the gap from design and modeling to day-to-day operations. This gives you the tool set for an integrated end-to-end solution from engineering and design on through production/erp to Microsoft Dynamics GP, Sage Accpac, Simply Accounting and Fortsum Acomba financials. We are producing goods faster than ever before and have boosted production by at least 50%, (Co-owner, Elka Suspension Inc.) Web: Toll Free: sales@geniuserp.com (English) (French)