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CASESTUDY

Roadmap ERP Inks the Best Solution for the Digital Concerns of Pen Manufacturing Companies

www.roadmapit.com

mktg@roadmapit.com Integrate Innovate Succeed

Brief Company Pro le e Pen Manufacturing Company was established during the mid-1990s and is located in Karnataka, India. e company is powered by its tip manufacturing facility and tool room, which has the capacity to design, develop and manufacture molds. Presently the company has the capacity to manufacture 0.5 million mechanical pencils and 1 million Ball Pens and is one of the largest exporters of pens and mechanical pencils in India. e entire production of the company is exported.

Brief Company Pro le e Pen Manufacturer has a state of the art Tool room equipped with CNC machines, CNC Sparking machines; super drilling machine and other machining facilities that provide high precision mold components for Injection Pen/Mechanical Pencils Molds. e organization has around 80 injection molding machines and automated assembly machines that are capable of producing over 50 million parts, which can be assembled to manufacture millions of Ball pens, Gel Pens and Mechanical pencils. e company follows Failure Mode and E ects Analysis (FMEA) process and Production Part Approval Process (PPAP) to ascertain the manufacturing of good quality products. To enhance its Production mechanism and to maintain high quality standards, the company has an online monitoring system, LAN with call escalation, built in Vision system / Poke Yoke in injection molding and assembly machines, FIFO system for WIP and Finished Goods, Preventive and Conditional based maintenance system, process control approach, and a well-equipped quality testing Lab. To ensure employee safety and skills development, the organization adheres to environment and personnel safety standards and provides training and continuous improvement programs.

Reason to Choose Roadmap e company had Excel and & Manual Registers to handle data transactions & reports, and there was no codiďŹ cation for items. e Pen manufacturer has many products and di erent colors, so it could not monitor the stock transaction in the following processes: Inventory Control & Stock Transactions Quality Control System Generated Reports Monitoring Stores Activities Production Related Issues Bill of materials for all products

Reason to Choose Roadmap Other aspects that compelled the organization to go for an ERP were: To avoid the existing Excel & Manual Data registers To maintain the class & subclass To systemize the existing oral communication in stores consumptions To avoid the production of more items than in the orders To generate systematic reports through ERP To identify the estimated mold life in injection molding To monitor machine idle times To generate machine History To rule out the pain points thus experienced, the company realized the need for an e ective ERP solution and called for suitors. Of all the ERP solutions that responded to the Organization's call, it found Roadmap ERP to be the technologically and economically best-ďŹ t system with the most amicable answers to address each one of its pain points.

The Pen Manufacturer's Pain Points Addressed by Roadmap ERP Inventory Control & Stock Transactions e Pen Manufacturer maintained SKUs "Store Keeping Unit" for its Fgs. e company could not check the stocks at di erent stages of Production like injection molding item, printing item, assembled item & SKU (FG). In all process, they could not check the QC & monitor the stock color-wise & product-wise. Roadmap ERP captures Machine, Tool, Shifts, and Mold details, and enables the easy monitoring of tool life and stock transactions at multiple stages easily. Roadmap created item codi cation for all items and also categorized the items like RM, SFG, and FG. î “e ERP provides the scope to check the QC and to monitor the stock color-wise & product-wise.

Quality Control e Company used manual register & manual report for Quality checking process. Roadmap con gured the inspection plans for Incoming QC, Line QC, Final Inspection, and Pre-dispatch Inspection. Based on the plans the items and its characteristics & speci cation are inspected and appropriates entries are made. Once the entries are done, the corresponding report against the plan is generated.

Monitoring Stores Activities: e Organization did not maintain Material Request/Material Issuance in the system, so there was a constant mismatch in the raw materials & consumables transactions. Based on the Production order, the Material Request and Material Issuance data are tracked by the Roadmap ERP system against each and every Production Order and Job Work. is ensures the maintenance of Stores in a Uniform Structure, and especially, by reducing the unwanted Cost. System Generated Reports e Pen Manufacturer maintained only manual registers and reports and required systematic reports in all areas. In all the modules furnished by Roadmap, the ERP captures the existing reports format and provides system generated reports for PO, Sales invoices, Packing List, Job Orders, Material Request Slip, Material Issuance Report, Stock Reports, etc. Production Related Issues Production users produced more items compared to orders. Runner/Raiser wastages were not monitored. More consumption for production. Roadmap ERP addressed all these issues and also helped better the existing system through the provision of the following facilities: e ERP provides the scope to manufacture both on a make to order or make to stock modes. MRP1 - Material Requirement Planning -Based on the Customer PO, the system runs MRP and releases the PO's and Job Orders. MRP2 - Material Resource Planning - Based on the MRP1, the ERP runs the Resource planning including manpower. Other Process Entries - Based on the Production Order the so ware schedules manpower and machine-power entries in the ERP, and enables the tracking of each and every entry for a Single Production Order, so that the Production Order for each and every Sales Order can be tracked. Production Order - e solution aids the input of Production Entries based on the Sales Order, and ensures the eradication of unwanted Cost by facilitating the tracking of the cost of Production Entries against the Sales Order.

Tool Life and Machine History - e Process monitors the entire history of the Machine and Tools and enables the concerned stakeholders to clearly view the cost of operating the machinery and have a complete idea of machine/tool idle/working time against every Production Order. Production Wastages - By ﬁnding the runners & raisers wastages against all injection molding transactions the system reduces wastages to a great level. Bill Of Materials for all products: e company did not have a Bill of Materials for all products. Roadmap ERP creates Bill of Material for all Products and accurately deﬁnes the input material for each production order. Roadmap ERP enables GST compliant inputs and outputs for Purchase, Sales and Finance oriented transactions of the Pen Manufacturer.

Implementation Success

Roadmap, through its Business Process Re-engineering (BPR) approach, understood the needs and purposes of the Concern's business processes. Roadmap's BPR experts eﬀectively collaborated with the Organization's core-team and succeeded in implementing the ERP on-time. e comprehensive integration of Roadmap full-suite ERP with the entire business process of the Pen Manufacturing Company has eased its management by integrating all its functional units from within and without. Roadmap ERP solution provides accurate details to precisely plan the procurement and production processes. Further, it empowers the Stakeholders to make faster and better management decisions by providing crucial information in a timely manner. e ERP has ultimately delivered high ROI by totally solving all the snags that were pulling the company behind from functioning smoothly.

î “e comprehensive integration of Roadmap full-suite ERP with the entire business process of the Pen Manufacturing Company has eased its management by integrating all its functional units from within and without. Roadmap ERP solution provides accurate details to precisely plan the procurement and production processes. Further, it empowers the Stakeholders to make faster and better management decisions by providing crucial information in a timely manner. î “e ERP has ultimately delivered high ROI by totally solving all the snags that were pulling the company behind from functioning smoothly.

Integrate Innovate Succeed

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