R.C. INFORMATICA S.R.L. INOVATIVE ERP SOFTWARE SPECIALIZED FOR FOUNDRIES FONDWEB

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1 R.C. INFORMATICA S.R.L. INOVATIVE ERP SOFTWARE SPECIALIZED FOR FOUNDRIES FONDWEB YUSUF SOYDİNÇ

2 INDEX SUMMARY... 3 ABSTRACT THE BORN OF FONDWEB THE WORKING PRINCIPLE OF FONDWEB OFFICE MANAGEMENT CLIENT MANAGEMENT SUPPLIER MANAGEMENT WAREHOUSE MANAGEMENT MODEL MANAGEMENT TECHNICAL MODEL MANAGEMENT CORE MANAGEMENT PRODUCTION CYCLE MANAGEMENT CUSTOMER ORDER MANAGEMENT STATISTICAL CHART AND GRAPHICAL ANALYSES ANALYTIC SOLUTIONS FOR DISCARD PRODUCT STATISTICAL ANALYZE OF CLIENT ORDERS STATISTICAL ANALYZE OF TOTAL COST CHART AND DOCUMENT MANAGEMENT INTEGRATION OF FONDWEB FOR AUTOMATIC PLC SYSTEMS KEY WORDS REFERENCES

3 INONATIVE ERP SOFTWARE SPECIALIZED FOR FOUNDRIES Yusuf SOYDİNÇ University of Cassino and Southern Lazio M.Sc. Global Economy and Business, Cassino, ITALY M.K.Ü. Mechanical Engineering, Hatay, TURKEY SUMMARY The purpose of this study is to identify relationship between the production management and cost management system. This integration allows you to manage the moulds, casts and equipments in real time. One of the most important utility provided by this study is momentary possible to observe the cost per kg and per unit. The essential part of case study the ERP software FONDWEB is able to provide immediate information about the discard product effect at the total cost chart. It includes detailed information concerning the reasons of the foundry losses and discard products. ABSTRACT FONDWEB software is specialized only for all type foundries (Gravity Sand Casting, Die Casting, and Shell Casting) and it has been built by RC Informatica to speak the foundries language. 3

4 1.1 THE BORN OF FONDWEB FONDWEB was born in the foundry in 1994 by a collaborative working group of consisting foundry managers, metallurgical engineers and informatics engineers. RC Informatica specialize the software only for foundries and builds it to speak the foundries language. It has all the posses for increasing the efficiency and productivity of the foundries. Combination of all the components in software will provide innovative, simple, integrated absolute solutions for foundries to increase their value, capability of productiveness and competitiveness. In an evolving global business, managers of the foundries need to get information everywhere in real time. FONDWEB is an ideal computing solution to develop and meet requirements of foundries. 1.2 THE WORKING PRINCIPLE OF FONDWEB FONDWEB is able to serve technical information for following sections; molds and equipment management, programming and monitoring the production cycle, final balance cost of the production (per kg and per unit), traceability of cost and orders, foundry losses and defects management, quality control, packaging and shipment management, documentation and certification management. It is possible to monitor and export any statistical charts, graphs and tables on excel. The user of the software is able to send and attach any document in an to other users or to clients. One of the most important utility provided from the software, the user can monitor the active production cycle from everywhere via network connection. 4

5 The director confidentiality can manage in the access to data, program authorizations and the possibility of limiting single fields to authorize users. The detailed information about the case study is going to be discussed in coming sections. 1.3 OFFICE MANAGEMENT CLIENT MANAGEMENT Authorized user able to modify, add/ remove new clients and able to manage the current client lists. Every customer called with a unique code. It provides information about affiliate address of the client, payment type and historical orders with payment details SUPPLIER MANAGEMENT This section provides detailed information about raw material or intermediate material suppliers. The user can add/remove and modify any information about the suppliers. Also, it is possible to control the historical transactions. Regarding to past operations it prevents the delivery of the material and gives information if there will be any delay in the process WAREHOUSE MANAGEMENT It contains information about the stock quantity with variable SI unit measures. Each material has a special coefficient for selling and buying. The price of each product is in the list with historical values. It is possible to compare the present values with past values. Also, each component coded with a different localization. It helps the user to find the each product without any trouble. The software allows you to use the quota management. 5

6 This provides possibility to user in order to access the information about momentary stock potential of the company. 1.4 MODEL MANAGEMENT TECHNICAL MODEL MANAGEMENT Each model has a code with 12 characters. First 6 character represents the client code, following for is the model code and last 2 represents the production method. It is possible to manage the dimensions of the molding boxes also the number of the models at the molding box. User is able to control the important parameters such as alloys type, optimal melting degree of alloy, and sand type at this tab. The yield of the casting calculated automatically by the program. It is automatically possible to observe the medial weight of the product. Figure 1.1 Technical Details of the Product 6

7 The software provides the discard product percentage for each production. This helps to company to set the right marginal cost in order to maximize their profit. The display of this tab presented at figure CORE MANAGEMENT Each product may have one or more cores in molding box. FONDWEB provides ability and traceability for directors to collect all the technical details of cores in one unit. This allows you to manage the total cost of the product per unit and per kg PRODUCTION CYCLE MANAGEMENT At this phase user can manage the production steps of the material from the beginning until the end of the production processes. A sample of process can begin with modeling, tooling, molding, assembly, casting, breaking the mold, sand bath, 1 st quality control, spiral forming, cutting process, definitive QC, chemical and physical tests. User has to define the process time for each step. Regarding to this information FONDWEB can provide the cost of each production step. 1.5 CUSTOMER ORDERS MANAGEMENT FONDWEB provides to user ability to visualize the customer orders. It is possible to print-out the confirmation of order and send it to client via . User can modify or edit the report in a sense of reviewing the data. In this tab user can also manage the delivery process, find information about approximate delivery time and unexpected delays. For each product it is possible to print-out shipping document and share it with the client. 7

8 1.6 STATISCAL CHART AND GRAPHICAL ANALYSES This is one of the most important utility provided from the FONDWEB. User can evaluate every single detail of production by using the statistical methods ANALYTIC SOLUTIONS FOR DISCARD PRODUCTS At this tab user is able to analyze the total discard products of the total production. User can have the chart or the table on the graphical interface with all the description. This allows the director to control the production departments and solve the related problem in order to avoid production errors. FONDWEB can create a chart with percentage details of discard motives. The graphical explanation presented at figure 1.2. Figure 1.2 Statistical Analyze of Discard Products As it s presented at the graph it is easier to see the real reason of the wrong production. Each bar represents different motive. At this graph, the red motive has the highest percentage for discard production. 8

9 Also at the top of the chart user can see the total production amount and total discarded products presented by kg and by piece. This allows manager to minimize the discard production and maximize efficiency of the production cycle STATISTICAL ANALYZE OF CLIENT ORDERS FONDWEB provides possibility to analyze the client orders for different periods. It can be daily, weekly, monthly, quarterly, seasonally and yearly. This helps to director to compare the demands of the clients for product within the time. Director can have the analytical breakdown point for each product. This provides information for each specific client if demand increases or decreases for the defined period. The chart presented at figure 1.3 is the graphical interface of client demands. Figure 1.3 Comparison of the Clients Demand 9

10 1.6.3 STATISTICAL ANALYZE OF TOTAL COST FONDWEB provides the management of the direct and indirect cost for the director. This helps to set the most efficient price for each product in order to maximize the profit. Director has to define all the technical details for each production phase. The important direct cost are the cost of raw material, cost of furniture, cost of man power, cost of forming processes, cost of quality control and cost of delivery. It is important to define the cost of each utility per minute, per second or per product. Once user define all the information, it is possible to obtain the total cost of product (per kg or per piece) within a second. Regarding the discard product percentage user can see the effect on the total cost at the same moment. Figure 1.4 presents the graphical interface for total cost analyze. This utility of the FONDWEB software provides ability to control the certain total cost with a right margin. Figure 1.4 Interface of Total Cost Management 10

11 1.7 CHART AND DOCUMENT MANAGEMENT It is possible to print-out, edit, export and send every single chart presented by FONDWEB. This allows flexibility to manage the documents for directors. User can share the necessary information with the client in any time via or fax. 1.8INTEGREATION OF FONDWEB TO AUTOMATIC PLC SYSTEMS It is possible to integrate the automatic systems to FONDWEB. This provides possibility to monitor the production in real time. It is connected to piece counting scale via barcode readers. Each product has a unique code therefore it is easy to follow the produced products. The working principle of the system is based on PLC and IBM I series. Fixed or portable barcode readers deliver the data to PLC system. PLC is transferring the data to IBM I power series. IBM server distributes the data for the personal computers, Ipad or smart phones. It gives information about number of molds, discarded products, start/end time of the production, breakdown of the system. User can analyze the productions in pieces and weight, analysis of foundry losses per %, analysis for melting code/ alloy/ system and graphical representation of the foundry losses. 11

12 KEYWORDS FONDWEB: The name of the ERP software ERP: Enterprise Resource Planning PLC: Programmable Logic Controller MANAGEMENT DISCARD PRODUCT ANALYZE TOTAL COST MANAGEMENT PER KG AND PER PIECE (UNIT) 12

13 REFERENCES The FONDWEB software built by R.C. Informatica S.R.L. engineers. The technical information and explanation provided from their experiences and observations. 13