Challenges and Opportunities

before Foundry Industry

Expedite sales order management and

provide audit trails

Streamline production planning and execution

Improved quality management

Improved inventory management

Improved Foreign exchange management

Improved Export documentation

Automate updation of Accounts receivable and Accounts payable

Speed up financials reporting

Provide reports necessary for legal compliance

Improved speed and accuracy of product cost determination

Improve information accessibility and allow

multiple user authorization levels

Increase data security

Provide exception reports, alerts

Replace disparate legacy systems with a single, comprehensive, integrated solution for enterprise

resource planning

Eliminate redundant data entry

Functionality that spans the complete range of business requirements.

Complete integration that eliminates the need for entering the same

data multiple times and manual errors.

Global presence.

SAP's reputation and stability, helping ensure long-term support.

Steady stream of updates to meet changes in business and

legal requirements

Better order to cash managementEnd-to-end order-to-cash process, from the point of sales quotation - receipt of an order -manufacturing/purchase planning -manufacturing/purchasing - delivery/ packing -invoicing - receipt.Sales order processing - the first step before production planning can begin. With all the automation SAP Business One provides, along with its single point data entry, many manual steps will be eliminated and sales orders can be processed 15% to 20% faster than ever before and manage them much more effectively.Each transaction has audit trails, which make it far easier to find the right person when a problem or an issue arises that threatens to slow things down.On sales order finalization, the next step in fulfilling orders is production & purchase planning.Our Foundry Solution calculates raw materials for casting; keep both weight and number of pieces in all reports. It even helps in recycling of materials i.e foundry return generated from different stages of production like casting, machining, grinding, painting, crating etc. to be recycled for use in charging.The Solution has quality control functionality that allows monitoring incoming, in-process and final quality inspection.The Forex (foreign exchange booking) Solution help to realize maximum benefit from foreign exchange advance booking and its realization.The Export documentation has made cumbersome export documentation easy and linked with all functional documents.

Integrated financialsIn accounting and finance, standard SAP Business One functionality helps to automate, streamline, and integrate the accounts receivable and accounts payable processes.Preparation of integrated financial reports is far easier.

Accurate, top-quality reports on overall financials, including branches is much quicker.Period-end financial statements are available immediately.

Finance is benefitting in other ways as well from SAP Business One. Any organization is more nimble in responding to ever-changing legal requirements that impact the information that reports must contain.

In addition, with all the relevant information in one integrated solution, it is much easier to roll up overall costing for products.

Control over costing gives profitability analysis.

Process Flow in SAP Business One -Foundry Solution

Customer Order bookingMRP (Material requirement planning) based on customer order and/or sales forecast.System generated production order for different stage of production i.e Casting, Machining, Grinding, Special Painting, Crating etc.Mix Plan for chargingChemical composition of all raw materials is maintained at the time of receipt.Mix plan based on desired chemical parameters of liquid metal - Percentage of raw material required to produce certain quality of liquid metalDaily charging based on Mix Plan - Consumption of raw material and receipt of Liquid MetalProduction of Casting - Consumption of Liquid Metal, receipt of Cast Component and Runner/ Riser based on predefined Bill of Material.Production of Machined Component - Consumption of Casted Component and receipt of Machined Component as per predefined Bill of Material.Production of Finished items - Consumption of Machined Component and receipt of Finished GoodsDaily production reporting - Moulder wise/Contractor wiseRunner/Riser/Foundry return generation at different stage of productionRejection of item at different stage of production with rejection reasonConversion of rejected item to Foundry ReturnQuality reporting at incoming material, in process and final stage of productionDispatch, invoicing and export documentation

Salient points of the customized solution

Template Bill of materialTemplate Bill of Material for Finish Goods where components and consumption ratio of components is same.Bulk production order creator for items produced from same recipe.

ForexMaintaining Bank wise/Currency wise deal register and utilization of the dealCross currency deal registerPacking credit loan functionalitySpot rate fixingDifferent MIS reports to book a deal and optimum utilization of that deal.

Template Based CostingTemplate based production costing report, taken for a particular period, has the following salient features:Here we define the layout, materials to be taken for consumption, ledgers to be taken to capture Other/indirect cost-thus keeping it configurable for the user.The report shows: Produced good castings (inclusive of mould box)

and bad castings Consumption of materials like Pig Iron, Foundry

Return, Hard Coke, Ferro Alloys, Scrap etc. and hence consumption per unit of production.

Other/indirect cost captured through defined ledgers and hence other/indirect cost per unit of production.

Total production cost and hence total cost per unit of production.

ReportsProduction

Contractor wise production report

Department wise production report

Weekly rejection report

Detail production report

Production analysis

Rejection analysis

Charging report

Liquid metal consumption report

Moulder wise production expenses detail &summary

Charging consumption report

Customer order wise production status

Quality Moulder sand characteristics Melting process

control Ductile Microstructure Tensile Properties Report Tensile Testing Report Composition of Metal Analysis Report Load Testing Report Field Dimension Inspection Report

Purchase Receiving and Analytical Register Report-Iron &

steel. Hard Coke , Ferro Alloys , Additives, Limestone.

Way bill utilization register

Sales Sales Order related billing status Duty draw back

statement Focus report Forward booking deal register Foreign currency

receivable report Packing credit loan register Currency wise deal register

Stock Stock holding report Stock summary report Customer wise stock status report Item group wise stock transaction summary report in weight

Tax Excise & Service Tax register Tax report register - VAT/CST Tax report summary - VAT/CST Export register

Domestic sales register

Export Documentation Sales Order acknowledgement Final Packing List

Final invoice Excise Invoice

ARE1

Monthly declaration of Shipment

Calculation Sheet of Rebate Claim

Certificate of origin

Different customs invoice

QUICK FACTS

SummaryDesigned specifically for small and medium foundries. It helps streamline your end-to-end business processes and instant access for any information. Our solution is cast in your requirement mould touching your core areas.

Business ChallengesAccess the right information at right time Duplicate data entries and errors there fromDisparate legacy system causing inconsistency Building a closer customer relationship Inventory tracking Data security To move with time

Key FeaturesInput material composition monitoring

Production Planning

Mix plan for charging

Production recording

Quality recording

Delivery monitoring

Export Documentation

FOREX monitoring

Template based costing

Customised reports

Business BenefitsSpend more time growing your business proactivelyAct on instant and complete informationRespond quickly to customer needs by instantly accessing decision making information

Eliminate redundant data entry and errors with a single, integrated system

Form closer customer relationships via centralized informationLower your technology costs and achieve faster time to value by a system which can be implemented quickly, is uncomplicated to maintain

Scalability of the system with growth

System generated alerts on exceptions