Embed Size (px)
DESCRIPTION
Do you think existing ERP (Enterprise Resource Planning) not suitable tomeet the requirement of the foundries? Why? What could be the solution? ERP is not the new term for most of the foundryman. ERP was introduced withthe main intention to handle large data of manufacturing. Existing ERPfulfills the requirement of foundries? Probably not because today thebiggest requirement of foundry is "Single system used by all the departmentsof foundry" as most ERP does not include many vital operation/flow/processof foundries. Does your ERP include Tool-Pattern management, production planning, Coreproduction, shift planning, Record material composition from Spectrometerfor each heat, Historical data of each quality test? - Probably most of theERP does not include this. Can there be any solution? - RGU GmbH, Germany has been developing FRP -Foundry Resource Planning think beyond ERP. Dedicated FRP system developedonly for foundries not applicable for other manufacturing process other thanfoundry. Over 120 foundries across pan Europe are running successfully onRGU-FRP software since last 30 years. Limitations of the existing ERP:1) How to calculate cost of casting part or total production/day:If you are Foundry owner or top level management, the biggest challengewould be, to calculate the CTC (cost to the company) for a single part orcost of total production/day etc. Most of the foundries never know thiscost exactly, because foundry deals with so many possibilities, andnonlinear flow of process which are not part of the existing ERP. Tocalculate this foundries should consider design & simulation cost, toolmanagement, rejection, scrap, energy cost, slag, material cost variations,labor cost, unplanned activities (machining, external machining/services orsurface improvement), underutilization of man or machine, idle machine timeand cost, return circuit etc. Any solution? - RGU.OPTI - FRP software readbelow.2) Resource planning Most of the ERP system cannot do the fully resource planning, because itdoes not have modules for production planning, Fettling & machining, qualitycheck/test. If the foundry is able to specify each the resources requiredfor their casting part, and if ERP allows to record all the requiredresources in the system, the remaining job would be very easy for foundriesto order, track, store, use and dispatch the required resources. But if ERPdoes not integrate with production, tool room, quality it would beimpossible to streamline your resource planning, and despite use of ERP itincreases burden of lots of work, email communication or miscommunication,paper work despite using the technology. Can any ERP software do completeresource planning even for new order booked? - YES IT IS POSSIBLE withRGU.OPTI - FRP software read below.3) Tool managementTool & pattern management is one of the biggest need of foundry which ismissing in most ERP. For any production planning concern person should knowavailability of tool, mould box, or die casting machine. Tool & patternmanufacturing, required time for making, cost, maintenance time and costetc. If ERP does not included this how could one calculate exact cost ofpart or total life cycle of tool cost? Can any ERP system includestool-pattern management? - YES IT IS POSSIBLE with RGU.OPTI - FRP softwareread below. 4) Design & Simulation data Foundries do various trial and error, or try possible ideas of variousgating system design for which they have various drawings for each trial, 3DCAD model, Casting simulation data, if it is not recorded on ERP how wouldyou consider required time, effort and cost to develop one part? And even infuture when similar part , it would be very easy for foundries to see thevarious design they have done in past and calculate cost and required timebased on past history saved. Does any ERP really in
Citation preview
Highlights of OPTI.kompakt:
Planning• Integratedoperationsscheduleandparts
listasacontinuousresourcesplan• Simple,fastandexacttothelastcentcal-
culationofallmanufacturingsteps• Takesjustminutestoenteranewpartby
duplicatingandadaptingresourcesplans• Similaritysearch• Integratedmaterialsdatabase• Providesenquirieswithscheduleswhileta-
kingthecompleteschedulechainintoac-count
• Automaticmaterialrequirementsanalysis• Workflowandrelease-controlledinterdepart-
mentalwork
Production• Displaysallmanualandmechanicalmould
processes• Automaticschedulingacrossallmanufactu-
ringstepstakingcapacitiesandbottlenecksintoaccount(MRPII-run)
• Flexible,scalablefeedbackchainsinpro-duction
• Procedure-controlledadministrationofalltoolsandpatternsformouldsandcores
• Integratedtestplanningandcertificatege-neration
• Detailedplanningforeachdayorshiftusingadd-ons
• Seamlesslinksbetweenfoundry-specificmodulesensuresynchronisedprocesses
Reporting/GIS•Integratedweb-basedGIS,(FoundryInfor-
mationSystem)–continuousinformationsystemaboutalldatarelevantforthepro-ductandproduction
•Managementinformationfordecision-ma-kers
•Comprehensivestandardreportsandrealtimeevaluations
•Visualplanningusingtheutilizationandca-pacitycockpit
•Opendatabase
Compact price Complete coverageUnrivalled performance
Medium-sized foundries have special requirements for their corporate soft-ware. OPTI.kompakt provides youwith anoptimised FRP system (Foundry ResourcePlanning)speciallytailoredtotheneedsofsmallandmedium-sizedfoundrieswith5ormoreworkstations.
Every foundry is special. TheOPTI.kom-paktmodularprinciplemakesitpossibletoadaptitflexiblytoyourrequirements.Fromdetailedplanning,serviceplanning,claimsandknowledgemanagementthroughtoin-tegratedchargecalculations–wedeliverawholerangeofmodularsolutions.Thisalsomeans that OPTI.kompakt can grow withyourcompany.Inadditiontoitsinformativeand easy to operate user interface, OPTI.kompakt is convincing on so many levels,with its simple handling, comprehensive
displaysandthefactthatitintegratestypi-calfoundryprocesses.Allofthisisprovidedatanunbeatablepricecombinedwithshortimplementationtimes.
More than 30 years of experience and process structures from more than 100 foundries have gone into our FRP system. OPTI.kompakt consolidates ourdevelopmentsinapre-configuredstandardsolution.
Combine this with our consultants’ ex-pertise and you will soon notice that youhave not just bought a software solution,youhavealsogainedalongtermsuccess-orientedpartnerforyourcompany.
We live and breathe casting and struc-turing your processes - Know-how Cast in Software.
THE COMPACT FRP SOLUTION
OPTI.kOMPAkT
The core functions of OPTI.kompakt:
Planning & CalculationIntegrated resources plan:OPTI.kompakt is fully aligned to thewayfoundries reallywork.That iswhy, incontrast toother systems,wedonotconsiderworkschedulesandparts listsseparately.Alloftheresources needed for themanufacture of a particular cast part aredisplayed within a tree structure in a multi-step resources plan. Itdoesn’tmatterwhetheritconcernsself-producedcomponents(cores,patterns,melt),purchased items(filters, feeders,sand)orworkpro-cesses(pattern,clean,finish,internallyorexternally).ThelogicoftheresourcesplanisintegratedthroughoutalllevelsofOPTI.kompakt.
• Simpletocreatenewpartsandvariants• Fast,reliablecalculationofallorspecificlevelstakingall
possiblecostsintoaccountatthetouchofabutton,includingpurchasedpartsandexternalservices
• Similaritysearchesforarticlesalreadycalculated• Calculationsarchive• Administrationofalltechnicalparametersinthepartsmaster• Integrated,comprehensivematerialsdatabase,withsaveable
testplans
SalesThesalessectionguaranteesreliableandclearcreationofoffers,or-derprocessing,dispatchorganisationandinvoicing.
• Ittakesjustafewdaysfromreceivinganenquirytosendingouttheoffer
• Supportforalltypesoforder,suchassampleandfirstsample,individual,seriesandmakeandtakeordersforproductsaswellasforpatternsandtools
• Savesallcustomeragreements,awidevarietyofMTZandETZmodels,allmetalpricelistswithallcolumnsandtherelevantvalues(LME,VAWetc).Allsurchargescanbesavedspecificallyaccordingtocustomers,parts,materialsorprocesses.
• Problem-freeadaptationwithinflationincreasesandautomaticinformationtothecustomeraboutpricechanges
• Displaysawiderangeoflogisticsprinciplessuchaspreview,fixedorders,consignmentstockorcommercialgoods
• Seamlessinteractionbetweentheproductionandcontrolplan-ning:fastfeedbackregardingcustomer’spreferreddates
PurchasingInthepurchasingmoduleyoucanorganiseyourcompany’sprocure-mentactivitiesclearlyandefficiently.Alltheinformationwhichisnee-dedbythepurchaseraboutsuppliersandpurchasedarticlesissavedin the master data and linked with storage/consumption and priceunitsaswell asa varietyofparameters for controllingprocurementandtechnicalspecifications.
• Administrationofallthedifferenttypesoforderdetailssuchasframeworkorders,individualorders,manualandautomatedordertracking
• Detailedpricesheetfunctionwithpriceconditionssuchasamounts,discounttables,deliveryconditionsandmetalprice-lists
• Materialrequirements,purchasedpartsandexternalservicesarerecordedaccordingtoordersorgeneratedautomaticallyasaccumulatedweeklyamountsortheycanberecordedmanually
• Takesintoaccountminimumavailablestockrequirements,orderlotsizes,replacementtimesandtheorderswhichhavealreadybeentriggeredOverviewprovidedatanearlystageinordertooptimiseorderquantitiesfromthepointofviewofcostsandliquidity
• Integratedreminderanddunningprocessforsuppliers.
Production and control planningThePPS-Systemistherightinstrumentfortheoperationalandstrate-gicplanningofyourproduction.WiththePPS-System,theschedulingandcapacitysituationcanbecontrolledandmonitoredquicklyandre-liablyfortheshortandlongtermandforallschedulinglevelsandbot-tlenecks.ThePPS-Systemshows itsparticularstrengths inplanningandsynchronisingmould,meltandcastingprocesses.Thedifferenttypesofcontinuousanddiscontinuousprocessescanbesynchronisedforthedifferenttypesoffoundryandavailabilitiesandcapacitiescanbechecked:
Allresourcesataglance:TheresourceplanistheessentialtoolforFRP. Foudry-specificbilloftools:Releasestatus,usage-listandlifecycle
RGU & Auto Design Online–Yourpartnerforconsultingandprogramminginthefoundryindustry.
• Toolavailability,preparationandprovisioningoftools,mouldingboxandpitavailability
• Coordinatesthemouldingshopandcoreproduction,ifnecessa-rytakingintoaccountthepatternboardandcoreboxavailabilityandcombinations,provisionofliquidmeltforseveralmouldingshopareasandmaterialqualities,ifnecessaryformationofcastingbatches
• Takesaccountoftherequiredcooldownandholdingtimes• Processandcapacity-utilizationforfinishingcastparts,ifneces-
sarywithexternalservices• Formationofheattreatmentbatches• Integrateddetailedplanningwithfilterfunctionsasanadd-on• Simpletosetupsensiblefeedbackchainsforseamlesstracea-
bility• Providesfoundryworkerswithinformationviatheintegrated
foundryinformationsystemwithchecklistfunctions,particularlyforcriticalwork-steps
• Automaticallygeneratescomprehensivedocumentation
ThePPS-Systemcoverstheneedsofalltypesoffoundries,fortypicalseries producers as well as for discrete producers. It is possible toaccessthelatestvalidproductionplansonlineortotransferthemtotheproductionmanagementsystems,e.g.inmouldingplants,soastocontroloperationsinthecontrolcentre.
Materials managementThematerialsmanagementsectionprovidesthesolutionforefficientstockmanagementforallproductsandprimaryproducts,purchasedorstoredmaterialsincludingloadcarriers,containers,palletsetc.withdifferentinventoryaccounts.
• Plants,locations,quarantinestore,externalserviceproviders,consignmentstore,intermediatestore,dispatchstore
• Incomingandoutgoingbookings,inventoryandstockevalua-tionsderivedfromproductioninformationmessages
• Evaluatessemi-finishedandfinishedstock• Itemmanagement,articlescanbemanagedviaIDandbatch
numbersasinventory• Permanentinventoryviaoperationalsequencestatements• Variousevaluationproceduresforinventory
Pattern management / tool management• Patternmanagementcomprisingallthetoolsneededinthe
productionandtheirvariants(diecastingtools,patternboards,coretools,moulds,CNCtools,inspectionequipmentetc.)
• Displayscomplexpatternstructuresandalltechnicalparame-tersintheresourcesplan(withpatternpartslistandtoolcard)
• Monitorstool-life,numberofcastingsandmaintenanceintervals• Alltoolprocessesrecorded,(fittingtimes,repairs,provisioning,
cleaning,dispatchetc.)• Monitorstoolavailability(castinglimitexceededduringproduc-
tion,toolisbeingservicedetc.)• Createsseamlesslifecyclereports• Recordsandstoresdocuments(drawings,photos,Officefiles)• Toolamortisation• Releaseprocedure/blockingprocedure
Comprehensive information system and evaluations• Comprehensive,web-basedinformationsystem,accessiblefrom
allmasks• Integratedfoundryinformationsystemcoveringalllevels• Proactivemanagementinformation,automaticallyfreshonyour
desk• KPI–performancefiguresforallsensitiveareas• Workflow-components• Checkliststoaccompanyprocesses• Foundryworker’sinformationcockpit
»With OPTI.kompakt we have now got costs and production under control. Our expectations have been more
than fulfilled.«
Stephan Buchholz,ManagingDirector,Buchholz&Cie.GiessereiGmbH
OrderTracking:Exampleforworkflow-orientedprocesses Schedulingmonitor:essentialtoolforthescheduler
RGU GmbH
Karl-Harr-Straße1
44263Dortmund
Fon+49 (0) 2 31.4 19 97 0
Fax+49 (0) 2 31.4 19 97 99
www.rgu.de
ww
w.b
eier
konz
eptio
n.deAbout RGU GmbH
Since1984RGUGmbHhas been develo-ping standard technical and commercialsoftwaresolutionstosupportbusinesspro-cessesefficiently.
Based inDortmund, this company is spe-cialised in providing complete solutionspackages covering everything needed forproduction planning and control systemsin foundries and the metal processing in-dustry.
The result is corporate processes whichare structured so efficiently that businesssuccesscanbeplannedfor.
Thisisachievedbymeansofcooperation,preciseanalysisandskilledconsultingser-viceswhichtakeupthecustomer’sspecificrequirementsandputthemintopractice.
After more than 30 years in the IT sec-tor,RGUhasgrown tobecomeoneof theleading providers of innovative softwaretechnologiesforPPSsystemsinGermany.Throughout Europe more than 120 custo-mers now rely on PPS and FRP solutionsfromthisDortmundsoftwarecompany.
Other services from RGUThe fact that our products focus on thefoundryindustryisnocoincidence.Workingoneveryimplementationwehaveastrongteam of consultants who have their rootsinthefoundryindustry.Thatiswhywearealsoastrongpartneratyoursidewhen itcomes to providing product-independentadvice, for structuring foundry processesor when creating specification cataloguesfor introducingsoftwaresystemsinfound-ries.We know what we, and you, are talkingabout.
What does FRP stand for?FRP is derived from ERP, the well-knownabbreviation forEnterpriseResourcePlan-ning. Instead of looking at the often un-clearlydefined“enterprise”wefocussolelyon foundries, which have significantly dif-ferent processes from those described instandard ERP systems – and that is whywehavecalleditFRP–FoundryResourcePlanning.
We would be delighted to tell you moreabout OPTI.kompakt in person and lookforwardtoreceivingyourenquiry.
Orfindoutmoreontheinternetat.:www.rgu.de
Auto Design Online 212,ArpanComplex
Nizampura,vadodara
Gujarat,India
Phone:0265-2786774
Mobile:+91-9824247774
www.auto-design-online.com
