First what is ERP?
ERP stands for Enterprise Resource Planning, which is a business process management software that allows a company to use a system of applications integrated together to manage the business and automate many back office functions. These functions relate to technology, services, and human resources. ERP software incorporates all facets of an operation, including product planning, development, manufacturing, sales, and marketing. An ERP system covers the following functional areas. These groups are commonly referred to as ERP modules.
Most ERP systems reflect the vendor’s interpretation of the most effective way to perform business process. Companies that implement, vendor based reflection, reduce time-consuming project tasks such as configuration, documentation, testing, and training. This strategy will also help in compliance with industry standards.
You might start to visualize where does product development design process come into play. Properly implemented ERP systems can benefit the design process through a well suited model. This model would compile and organize areas to effectively implement the product development process. The following are areas in product development process where ERP can play a vital role.
In order to support an efficient product development process, relevant information models should be designed and implemented in the ERP program.
1.Control of Production Elements
Production elements are the schematic, models, documentation, materials, equipment, and any type of components. These elements are the building blocks for larger projects and are a sub-member of a completed assembly. For example, a system controller has many attributes before it needs to be design, manufactured, and installed:
All these components lead to the design, development, and construction of the final product. These are all referred to as production elements.
2.Production Breakdown Structure Holds the Integrity of All Relationships
Since the relationship of a product’s parts is a logical one maintained by the ERP system rather than a fixed physical relationship as represented on a schematic drawing, it is readily maintained for more than one relationship.
This will allows different views of part relationships in the assembly to correspond to various departmental needs (e.g., engineering and manufacturing product structures), while maintaining its consistency of the product’s definition through the ERP system.
The system provides the ability to hold not just the physical relationship between components and assemblies, but also other kinds of structures, such as manufacturing, financing, maintenance, or documented relationships.
3.The Vault - Store and Manage all Documents Related to the Product
In today’s process of product development, the product structure and design are developed in parametric and feature-based computer-aided design software. For electrical design this is commonly referred to as ECAD. The documents often have internal file association, within the ECAD software, for example schematic diagrams which depend on a corresponding model file. Fully assembled files rely on individual part model files referred in the assembly.
To support the product development process, the ERP system must provide an electronic vault with managing documentation capabilities. The vault should allow documents associated with production elements that enable internal file tracking within the same production elements. File tracking should not be done through localized records, but through product or assembly structures as it is stored in the ERP system. For a successful vault implementation all documents related to the product need to be stored and handled through the vault.
4.Thorough Control of Revisions and New Versions Through Check-Out and Check-In Processes
When a document is selected from the vault the other production elements involved will be downloaded to the local users station. The downloaded content is now a separate file from the ERP systems source. This allows the user to modify and make necessary changes to the file. The procedure is called “checking-out” and is written in the user’s local folders. The file checked-out will have all corresponding subordinate documents downloaded into the same folder. After the document is check-out the document is locked for all other users. This means that only the individual who checked-out the file can unlock it, or the system administrator.
Uploading the file back into the ERP system, in conjunction with PDM module, is called “checking-in”. This is where the new content modified is uploaded into the system for others to access once again. The ERP system manages the file by incrementally changing the revision number corresponding to the original version downloaded.
For example, if I download version #3 of a wiring harness schematic the uploaded file would be noted by a #4 and be considered a revision of version #3. The system will update the product details and note the date change. Once the file is uploaded back into the system the file is unlocked and all other users gain access once again.
5.Drawing Lists Provide a Link Between Drawings and Production Orders
Drawing items are individual parts called out on the assembly drawing. These include drawing items, drawing masters, and drawing revisions. ERP system allocates all resources associated with the design drawing and organizes it into a comprehensive list. Drawing lists usually center relevant information about the drawings in an organized manner. It is able to cultivate relative items, operations, and versions for the user to access. The list provides a link between the drawing and the production order.
6.Technology Operations - Transitioning From Design & Specifications to Production
Engineers can document all what’s needed for the product development, right in the ERP system. The ERP system allows staff on the manufacturing floor to access this information without any trouble. This will provide a detailed list of all resources that the manufacturer will need to build, test, and calibration the final product.
The manufacturing departments constantly face trouble allocating raw materials, resources, and streamlining output. The ERP system can assist in pinpointing drawbacks faced by the manufacturing process, such as problems created with time lags and product flaws.
The ERP system will help direct the operation in a progressive motion by keeping track of inventory, purchasing and procurement, supply chain planning, return management, and order management. The ERP system will help businesses to effectively coordinate and control their complex supply chain workflows and activities. The system will better manage all supply operations including sourcing, acquisition, and storage of all materials necessary for manufacturing production. It helps in the manufacture scheduling and management of all work in process, and compile a complete list of all items finished and stored in warehousing.
7.Identify the Precise Equipment Needs for Production
Equipment and manufacturing machines are essential for completion of product. If equipment and manufacturing machines are not functioning properly then production stops and brings down production rate. The ERP system has the capabilities to monitor the status of all equipment, based on user document reports. The compiled data is a full fledge list of all equipment items the company possesses. The ERP system provides information on necessary equipment and methods for developing a certain product. It will generate a list of the equipment that should be used in developing the component.
The ERP system provide information on the current status of equipment and manufacturing machines in house. It can report which devices are functional and which require maintenance or calibration. Properly functioning equipment is essential to build a fully assembled final product.
The ERP system can direct attention to area that are demonstrating a lower amount of productivity than normal. Properly informing users of the current status of production rate and if the falling progression is a direct result of insufficient equipment.
Conclusion
The ERP software system has many applicable capabilities for large and small companies. Control of product elements, production breakdown for each department, storing and managing product documentation, controlled revision and version system, compiled drawing list, transitioning from design and specification to production, and equipment identification for product manufacturing. ERP software offers a module method for completing a project from start to finish and offers great benefits for company productivity and efficiency.
How are you current in house operations going? Do you have your design process integrated with your ERP? What’s your experience with that?