Autosystems: ERP system

Autosystems
Automotive lighting designer and manufacturer in Ontario has 3 facilities Quality supplier to General Motors, Ford, Harley-Davidson, Mack Truck and others Installed TRANS4M ERP from Infor Global and ActivEntry shop floor reporting system Facility: 20 PC, 3 bar code printers

ActivEntry Shop floor system

Labor efficiency, Cost of production and Scrap information by work center, cell at end of shift Production change to avoid labor or scrap problem Know Crew size and Payroll cost Production managers have supervisory access to information from 3 plants

Modules Quality (1 of 2)
Compliance with Motor Vehicle Safety Standards: Federal MVSS 108 (US), Canada MVSS 108, Economic Commission for Europe 123 ECE regulations as of 2007 (ex. R6 for direction indicator, R37 for filament lamps) Assembly and parts beyond acceptable quality limits; identification, storage, causal analysis and corrective action Scrap rate (%) and recycle ratio by shift and shop

Modules Quality (2 of 2)
Defects analysis by equipment, worker, shop, product and process Rejects at which stage: materials receipt, manufacturing process, quality check, logistics handling or road drive Cost of quality vs. production, lost time and orders

Modules Human resource

Staffing plan: Permanent/temporary, level/skills, Place of work Salary admin: Hour/monthly rate, Worked hours, Benefits and Salary payable Shift allocation and Attendance Labor productivity vs. standard/target Quality index vs. standard/target

Other Modules
Manufacturing: Production Plan, Capacity Plan, Material Requirements Plan, Shift plan for Work center Distribution: Order management, Logistics plan, Purchase, Inventory, Warehousing Finance: Accounting, Budget, Funds flow, Production costing

Benefits
Standard paperwork and process in 3 plants Reduced scrap rate by 2.7% in 6 months Saves time spent on spreadsheets for planning Timely report used for improvement ideas at shop floor Better Shift plan and Shorter cycle time Decreased cost of transaction processing and MIS Agile organization with flexible structure and trained labor

Management Information Systems

Scheduled: Monthly Production, Productivity and Quality report, Cost of production Exception: Abnormal Scrap report by shift Demand: Query on low labor efficiency and high absenteeism Push: Shop floor performance report to managers at end of shift

Decision Support Systems

What happens to scrap rate if trained workers are absent and good machines break down? Impact of higher payroll cost on production How to improve process throughput and reduce cost of production? Optimum shift plan subject to cost, quality and process time constraints Data mining: Discover correlation between material source and production scrap rate

Future plan
Improve system integration (design and reporting), shift flexibility and standards compliance Extended e-business suites for CRM, SCM, procurement, decision support and portals Effective use of internet and mobile, scanners, printers and telecom network Evaluate and add DSS and EIS modules and tools