Roger Meloy
Manufacturing ERP for ETOs profiled in Machine Design Magazine.
Tag: erpc
New ERP Bookstore
In association with Amazon.com, ERPandmore.com now has a complete bookstore to assist you in finding ERP, CRM, PLM, or other software/process books. To access this new store, please click on “books” at the top right of the page. We hope you find this to be a valuable part of the site.
Feature – Lean-Enabled ERP
The old equation of part cost plus profit equals selling price is no longer accurate. Rather, a fixed or decreasing price less part cost yields profit. If manufacturers want to increase profits under this equation, controlling cost is key.
Increasingly, discrete manufacturers with blanket annual volumes are turning to lean-enabled concepts in an attempt to reduce waste (thus costs) to improve profitability. Some, however, have missed an important point: Lean manufacturing is not limited to waste reduction within pure manufacturing processes. It should also include all supporting activities, such as supporting ERP software. The entire organization should focus on eliminating inefficiencies wherever they occur, while continually improving quality.
The Japanese call waste Muda, which is defined as the opposite of value. Training employees to recognize and eliminate Muda can lead to reduced costs and, thus, improved profits.
There are eight types of Muda, motions that contain no value: motion, waiting, conveyance, correction, over-processing, overproduction, inventory and knowledge. (See sidebar) The goal is to eliminate activities that do not add value.
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Feature – Lean-Enabled ERP
Adding Value to ERP
During the 1990s, the vast majority of Global 2000 companies deployed client/server systems for enterprise resource planning (ERP) to replace their mainframe-based accounting packages. Some did it as part of the business process re-engineering (BPR) boom, others as Y2K upgrades at the end of the decade and others simply to replace aging financial systems. A recurring theme throughout the ’90s was that implementing ERP was difficult, expensive and frustrating. Study after study showed substandard returns for ERP investments. Perhaps because of this experience, many organizations have been very cautious about making changes to their ERP environments. However, doing nothing may be a costly mistake because most companies can use their ERP software more effectively than they are doing today.
Intelligent Enterprise Magazine: Adding Value to ERP
ERP Overview
This ERP Overview covers What is ERP, Brief history of ERP, Why is it necessary, Market Leaders and the future of ERP. What is ERP? Enterprise Resource Planning or ERP is an industry term for integrated, multi-module application software packages that are designed to serve and support multiple business functions. An ERP system can include software for manufacturing, order entry, accounts receivable and payable, general ledger, purchasing, warehousing, transportation and human resources. Evolving out of the manufacturing industry, ERP implies the use of packaged software rather than proprietary software written by or for one customer. ERP modules may be able to interface with an organizations own software with varying degrees of effort, and, depending on the software, ERP modules may be alterable via the vendors proprietary tools as well as proprietary or standard programming languages.
Brief History of ERP The focus of manufacturing systems in the 1960s was on Inventory control. Most of the software packages then (usually customized) were designed to handle inventory based on traditional inventory concepts. In the 1970s the focus shifted to MRP (Material Requirement Planning) systems that translated the Master Schedule built for the end items into time-phased net requirements for the sub-assemblies, components and raw materials planning and procurement.
In the 1980s the concept of MRP-II (Manufacturing Resources Planning) evolved which was an extension of MRP to shop floor and Distribution management activities. In the early 1990s, MRP-II was further extended to cover areas like Engineering, Finance, Human Resources, Projects Management etc i.e. the complete gamut of activities within any business enterprise. Hence, the term ERP (Enterprise Resource Planning) was coined.
Why is it Necessary? By becoming the integrated information solution across the entire organization, ERP systems allow companies to better understand their business. With ERP software, companies can standardize business processes and more easily enact best practices. By creating more efficient processes, companies can concentrate their efforts on serving their customers and maximizing profit.
Market Leaders The top five ERP vendors, SAP, Oracle Corporation, Peoplesoft, Inc. (now Oracle Corp.), JD Edwards & Company, and Baan International, account for 64 percent of total ERP market revenue. These vendors continue to play a major role in shaping the landscape of new target markets, with expanded product functionality, and higher penetration rates. SAP dominates the $6.7 billion ERP applications market in Europe with 39% market share. Oracle and PeopleSoft come second and third respectively, followed by SAGE Group and Microsoft Business Solutions.
The Future of ERP Industry analysts expect that every major manufacturing company will buy the software, which ranges in cost — with maintenance and training — from hundreds of thousands of dollars for a small company to millions for a large company. AMR Research of Boston says consolidation among the major players will continue and intensify. ERP vendors are expected to put more effort into e-commerce, CRM and SCM initiatives, with leaders redirecting between 50% and 75% of their R&D budget to these projects.
According to Gartner research group, the rapid evolution of ERP has already lead to a new corporate must-have, ERP II, which is supposed to help businesses gain more competitive edge in the future. The major difference is that ERP II involves collaborative commerce, which enables business partners from multiple companies to exchange information posted on eCommerce exchanges.
In the next tutorial we will talk about popular ERP Products and the Modules and Application related to them.
For more visualization of this article along with the screen shots and more visit with step by step instructions, http://www.exforsys.com/content/category/17/260/342/
Exforsys is a community of developers specializing in C, C++, C#, Java, J2EE, .NET, PeopleSoft, SAP, Siebel, Oracle Apps., Data warehousing, Oracle/SQL Server/DB2 and Testing. Please visit http://www.exforsys.com for more tutorials and for Interview questions http://www.geekinterview.com is an open database.
Causes of ERP Failures
Causes of ERP Failures
by Bruce Zhang
ERP is the acronym of Enterprise Resource Planning. Multi-module ERP software integrates business activities across various functional departments, from product planning, parts purchasing, inventory control, product distribution, to order tracking. ERP has transformed the way multi-billion dollar corporations conduct their businesses. Successful implementation of ERP systems could save tens of millions of dollars and increase employee satisfactions, customer satisfactions and sustain competitive advantages in every-changing marketplace. Corporate executives are often perplexed by the stories that how reputable corporations (Hershey Foods) have failed miserably and lost ten of millions of dollars in their ERP endures.
The failures of ERP projects are preventable if we can identify the common causes of the failures regardless the companies and industries that implement them.
- Image by Behrooz Nobakht via Flickr
An ERP system is the combination of ERP software, the business processes that the ERP transforms, the users of the ERP system, and the computer systems that run the ERP applications. The failures of a ERP project is often the result of the failures in one or more of those four components. The failures in computer systems (hardware and operating systems) are much easier to identify and to fix, so we’ll examine the failures in software implementation, business process and user acceptance.
ERP Failures -Software Implementation
Module-based ERP software is the core of ERP systems. Most ERP projects involve significant amount of customizations. Packaged ERP software modules have built-in functionality that work in a standard and simplified enterprise environment. However, every organization is unique in data requirements and business processes. It is the customizations that transform packaged ERP software into ERP software that meets organizations’ individual business processes and operations. Long and expensive customization efforts often result the pass of release deadline and budget overrun. Customizations may make the software more fragile and harder to maintain when it finally goes to production. Major changes may be required in the later stage of the implementation as a result of incomplete requirements and power struggles within organizations
The integration of ERP systems (http://www.sysoptima.com/erp/erp_integration.php) with the IT infrastructures also challenges ERP project teams. The use of appropriate implementation methodologies can often make or break a ERP project. (http://www.sysoptima.com/erp/implementation_methodologies.php)
ERP Failures – Failure of Accommodating Evolution of Business Processes
According to Anthony, R. A, business processes fall into three levels – strategic planning, management control and operational control. Organizations continuously realign their business processes of all levels in response to the ever-changing market environment. Many ERP systems aren’t flexible enough to accommodate evolution of business processes. Many ERP system need a major overhaul in every a couple of years.
ERP Failures – Failure of User Acceptance
The users of ERP systems are employees of the organizations at all levels. ERP projects usually modify the company’s business processes which create extra workload for employees who use them initially. They may not think that the workflow embedded in the software are better than the ones they currently use. Ongoing end-user involvement and training may ease the difficult in organization’s adaptation of new systems and new business processes.
Bruce Zhang has over 10 years experiences in developing and implementing ecommerce and ebusiness systems in various industries. He operates a website www.sysoptima.com that automatically aggregates the news and new articles in e-business (ERP, CRM, Supply Chain Management and Knowledge Management) from over 50 sources daily (www.sysoptima.com/newsbot/) to help corporate executives, professionals and consultants to keep up with the latest development in enterprise software market. The website offers a knowledge base for understanding business software from a systems perspective.
Another Related ERP Failures post
Causes of ERP Failures
ERP is in the picture for midsize manufacturers
Small and midsize manufacturers are increasing IT investment because they don’t have the IT architecture needed to compete in a demand-driven world. For many, this means going back to the basics: an ERP system that standardizes business processes, extends the company’s reach, and reduces overhead.
In a 2005 study of more than 550 companies’ ERP investment plans, only 27 percent of small companies “those with fewer than 500 employees” currently …more… (requires registration)
ERP and Lean
Chris Shaul
Today, many ERP vendors are offering Lean Manufacturing modules in their solutions. These modules propose to assist companies in their lean effort. The real question is to what degree will these modules be used. Can a traditional manufacturer going to a lean model utilize a lean software tool immediately? When implementing an ERP system, process redesign is a must. The change that must occur in order to support an ERP system can be tremendous. But can a company bite off and digest all of the changes? Which should be done first, lean or ERP? These are all some of the questions that a typical manufacturing manager who is about to embark on an ERP implementation might ask.
First, lets define a few things. Lean is the removal of waste within a process and the concept of pulling items to a demand. It is also known as the Toyota Production system as it was developed and refined by Toyota in Japan. ERP is a business process enabled by software tools. It is not a software project! ERP streamlines your information flow such that it parallels your process flow. ERP works to build product to a forecast and then execute a production plan and inventory purchases synchronized to meet the predicted and actual demand. Lean, on the other hand, uses a pull system to meet an actual customer requirement. Lean uses the philosophy of smaller batches and reduction in non-value-added activities to create a much shorter lead time, thus delivering faster to a customer. ERP does not by its’ nature drive efficiencies in the production process. It only provides planners with information on what is going on and allows them to plan faster. If the process is broken, then automating it with the use of ERP will only highlight the problems.
What is the answer? The answer for many is to implement lean as part of an ERP intiative. Some would say that it should be a predecessor to an ERP initiative. Lean purists will argue that you do not need MRP and MPS to drive the production. ERP folks will argue that MRP and MPS are essential to having parts in-house and suppliers coordinated with the production. The answer for most companies is a hybrid solution, where lean is driving waste from the production and supply chain process (although also in the above-the-shop-floor activities too), while ERP is being implemented, such that you are automating value added processes and not trying to replicated waste processes in your new system. MRP can be used to plan longer lead time items, or items with higher value, whereas a Kanban can be setup for the faster turning and less expensive items.
Working from the perspective of a hybrid model, lean principles and practices can be implemented just prior to the ERP initiative. Then during the ERP implementation, the lean concepts must be considered and utilized in the setup of the new system. Tools such as Value Stream Mapping can define areas for quick improvements. Then once those improvements are made, a process flow based on the future state model can be applied to the ERP system. For example, a production cell might be setup for a particular product line with kanban inventory control. This would change how you would define your production process in the ERP system. Better ERP systems can run in this hybrid mode of traditional MRP and modern Lean concepts. Some product lines might be more suited to the MRP/MPS method because of supply chain issues or because of the long lead times that are associated with the products. Other product lines might be easy to immediately switch to flow manufacturing. Because of this, you want a system that can handle both methods.
Using a hybrid model, you select and position the ERP system to work alongside your lean initiatives. By leaning out processes (above and below the shop floor), you are avoiding “automating the mess.” Doing so will shorten lead times, reduce inventory, reduce production costs, improve employee moral and streamline your ERP implementation. Be sure to choose an implementation partner that is familiar with lean and is able to work in a hybrid manner. What order should these two tranforming intiatives occur? It might be best to have the lean initiative lead the ERP intiative by a few months. Then begin to implement the system. But do not stop the lean transformation. That should now be an ongoing philosophy of continual improvement. Use it to your advantage during the ERP implementation. Doing so will only help you on go-live day.
References:
http://www.advancedmanufacturing.com/September00/informationtech.htm
http://www.lean-manufacturing-info.com
http://www.qad.com/company/newsroom/lean_value.html
http://www.mapics.com/software/EE/SyteLine/sl7-aps.asp
http://www.cmtc.com/
http://www.inventoryinc.com/complimentary.html
Chris Shaul is a Sr. IT Consultant and specializes about ERP selections and implementations.
