Metal & Machinery

metals

Metal industry production process is usually more complex, a metal product is made use of a variety of production processes, including casting, assembly, polishing and electroplating etc. Production process requires fast and flexible control. Even due to large project with several different duplicated molds, our ERP system can support in calculating and control in production process to minimize wastage, monitor on time delivery. Which can relieve stress in storing a serious backlog of finished and semi-finished products, taking up a lot of cash flow in the enterprise.

TTG ERP is a flexible enterprise IT solution that combines EPICOR ERP platform and special needs in metal industry. It perfectly supports in comprehensive management of all operational aspects of metal products business, including sales, customer service, product development, production scheduling (PMC),production planning, mold, projects, production, materials, warehouse, workshop, inspection, supply chain, finance, enterprise performance management, e-commerce. Help you quickly improve the production process on a variety of issues, to fully grasp the real-time information and overall operation in company.

– Support mixed mode of production, combining “according to a single production” and “Inventory mass”
– APS “Advanced Scheduling” is accurate for each processing machine scheduling, achieve the highest sales output
– MES “Shop Management” workshop production schedules in real time to reflect and bottlenecks
– Supports a variety of test mode to the entire production process and closely monitor product quality
– Be outgoing and processing processes, production schedules, quality and delivery for the entire monitoring
– Unified unit management material, completely solve the problem of engineering, procurement, storage of the same material in different units
– To “actual cost of production” basis, immediately grasp the actual profit and loss for each order
– Supports multi-company / multi-region / multi-language / multi-plant / multi-currency

metalcircle

As an industrial machinery or capital equipment manufacturer, you face unique challenges. In addition to complex engineering requirements, you must also answer to customer demands for higher quality, lower costs and faster delivery. With more than 1,700 industrial machinery and capital equipment manufacturers implemented in the midmarket, Epicor understands your challenges and will help you improve your operations and customer service.

Epicor for Industrial Machinery is a global enterprise resource planning (ERP) business software solution designed for organizations who manufacture machinery and capital equipment. The solution goes beyond traditional ERP to provide advanced planning and scheduling (APS), financial management, advanced cost accounting, product lifecycle management, CRM, preventative maintenance management and aftermarket field service, supply chain management and more.

The underlying service-oriented architecture (SOA) makes all of these functions available as secure Web services for easy integration with your Microsoft® Office applications and the global supply chain. The tools used for integration are components of the Epicor Productivtiy Pyramid.

Providing Solutions to Meet Your Business Challenges

– Reduce labor and material costs through implementation of lean strategies and efficient production management via workbenches
– Increase profits and maximize sales opportunities with customer relationship management capabilities
– Ensure high quality products are delivered to customers with robust quality assurance
– Maintain plant and equipment with preventative maintenance factored into production schedules
– Support production of complex products with product configurator and project management capabilities
– Provide comprehensive aftermarket service through mobile service engineers and part sales
– Improve visibility with a comprehensive end-to-end solution containing built-in dashboards

With award-winning integrated applications, Epicor for Industrial Machinery is a powerful yet easy to set up and use business software solution.


Epior Die Cast ERP Solution is specific to the foundry and cast metal industry.

Production flow

Generic systems do not tackle production flow in a foundry specific way, for example they do not allow for internal rework that tracks separate WIP (work in progress) to their dependent processes, allowing for flexible routing and capacity monitoring that can change under none-specific circumstances. They tend to have single manufacturing methods, and where they do track shop floor movement they don’t usually allow for multiple mechanisms of manufacture for the same part (making samples and experimental routing a nightmare). This idea also extends to customer returns and part rectification which can have a marked effect on capacity planning.

Parts break up and assembly

The breakup of what is essentially one part into multiple parts at a specific stage in production and the automatic identification of these parts is a serious issue with generic systems. In a generic manufacturing model most items consume other items, with cast metal manufactures the initial stages of production usually require grouping (by mould/box size etc) and initial manufacturing requirement is not a one for one basis, Epicor ERP handles not only generic assemblies but also the more complicated batch and break up requirements of the early production processes.

Batch splitting and parallel running

When an item is planned for production each process stage should be capable of being batch controlled and split out onto parallel processes each having its own capacity tolerances. Larger companies using generic systems for this solution end up creating outside ‘supporting’ applications to deal with this and a myriad of other issues.

Batch traceability

Some of the better generic systems have the ability to track codes or identities against individual items in production (most don’t) but they usually lack the integration as understood by cast metal specific software. They never automatically link to industry specific equipment (for example importing of spectrograph analysis or tensile test results) because they don’t understand what the data means or how it relates to the items being produced and therefore certification, traceability, and automation of documentation in the same area is none existent. The only way around this is again, more external ‘supporting’ systems.

Material inventory and costing

Consumption of inventory is usually covered by most generic systems (even where they don’t differentiate between purchased inventory, manufactured inventory, and non-stock services) and sometimes they even link to cost of sales in a very basic way. Because our ERP Die Cast Solution is cast metal specific it understands that materials consumed are not always costed at the purchased rate and can vary dependent on where they are consumed in production. Our ERP Solution can make adjustments to metal usage dependent upon scrap levels and planned manufacturing inflation, this in turn references purchasing price (which because we know not all purchased material is good material) can be inflated by actual wastage information. Generic ERP systems are incapable of this type of manipulation simple because they don’t have the specific cast metal information in order to tie it into their systems.

Tooling and dependent scheduling

The scheduling of dependent tooling (including patterns), usage, and its varying condition, will overstretch generic systems that don’t understand the relationship between part and tooling. For example if you monitor a tool it is reasonable to assume that the usage at its production usage is being taken into account. Even if the generic system can take into account tool usage it will not know how a part ‘breaks up’, and therefore its usage will be based upon the overall manufactured requirement (or worse still the order quantity). It will not understand the usage is per mould/box/plate etc and therefore the information it provides is of little use, unless you are prepared once again to support it with external systems…

Drawing and issue control

The ability to move production from one customer requirement to another can be very tricky within generic systems. They don’t always know about change control, drawing revisions, or changes in manufacturing methodology and don’t enforce control of such. This is usually ignored or fixed to an inflexible method of not allowing the movement in the first place which tends to force operators to allocate false amounts into and out of inventory in order to ‘get around’ the problem. We know the difference between issues, materials, varying production methods, and provide options for how the cast metal companies need to operate.

Quality control

Understanding the cast metal industry, our ERP solution has native functionality to stop sales orders, production booking, shipping, tooling usage etc when problems arise, not only on a capacity reporting basis but actual stops that can be controlled by production, pattern stores, sales, and so on. Every aspect of WIP booking, scrap, internal rework, customer returns, subcontracting, and inventory control are all controlled with data collection and analysis built towards gathering quality control information for Cast Metal Industry analysis. Collating this data in one place makes sense and provides the information needed to make informed decisions.

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