ENTERPRISE

PLANNING SYSTEMS
About The
Implementation
Company

Process
Workflow
Automation

Benefits/
Pre-ERP time
Limitations

New ERP Way Forward

About The
Implementation
Company

Process
Workflow
Automation

Benefits/
Pre-ERP time
Limitations

New ERP Way Forward

Introduction
 Established in 1951
 No. 1 in Asia in Gearbox manufacturing
 No. 5 in MHE manufacturing
 Turn over of ₹ 2000 cr. FY 10-11
 Manufacturing spread over 2L Sq. Meter.
 Located in VVN in Gujarat.
3 Main Division

Transmission

Alternate Energy Div

Material Handling Div
Transmission Division
Transmission

Geared
Helical Worm Coupling
Motor

A Std Fluid M

B Spl Geared C

C Flexible F

D K

P P
What all are the important things in B2B

 Reliability
 Cost
 Delivery time line
 Precision manufacturing complying
international standards.
Major Dept.
 Design
 Sales & Marketing
 Planning
 Manufacturing
Hobbing
Heat Treatment
Grinding
 Assembly
 Testing
 Q&A
 Painting
 Dispatch
About The
Implementation
Company

Process
Workflow
Automation

Benefits/
Pre-ERP time
Limitations

New ERP Way Forward

 Work Flow Start to End.
Order
booked W.O. to
BOM
by Sales Design Raw
dept Material
Gear Stock & Bought
Hobbing cutting out
Procurem
Heat Casting ent
Treatme Grinding for
nt casing
Machini
Assembl HT of
ng of
y casing
Casing

Testing QA Painting

Client
Dispatch Inspecti
on
About The
Implementation Workflow
Company

Process Benefits/
Pre-ERP time
Automation Limitations

New ERP Way Forward

Pre-ERP
Why ERP? Manufacturing and Distribution

• Improper Planning lead to more

inventory
Order Management
• Capacity Constrain.
• Delayed Delivery • Updation of stock took few days.
• JIT couldn't be implemented
• Product was costly & non-
Accounts competitive.
• Manual Invoice & excise GP.
• Dispatch details for insurance purpose
was not available instantly.
• Due to manual entry loss due to human
error was considerable.
• Delay in vendor payment
• Account receivables not available at
branch level immediately.
• Managing outstanding was huge task.
About The
Implementation Workflow
Company

Process Benefits/
Pre-ERP time
Automation Limitations

New ERP Way Forward

NEW ERP
 In The Year 2000 Elecon Eng Decided
to Implement ERP Systems

 OPTIONS Available :
 SAP
 ORACLE
 WINDOWS DYNAMICS
Company Decision
 ERP – Oracle Apps

 - 3 Major Modules
- Finance
- Distribution
- Manufacturing
 FINANC
E
ACCOUNTS
RECEIVABLE BILL OF MATERIAL

ACCOUNTS WIP
PAYABLE
COSTING
GEENRAL
LEDGER

DISTRI
BUTIO
N

MANUFAC
TURING
INVENTORY
PURCHASING
ORDER MANAGEMENT
About The
Implementation Workflow
Company

Process Benefits/
Pre-ERP time
Automation Limitations

New ERP Challenges Faced

Implementation
 Phase Wise Implementation

 Implementation within 23 Months

 - Finance
 - Distribution
 -Manufacturing
About The
Implementation Workflow
Company

Process Benefits/
Pre-ERP time
Automation Limitations

New ERP Challenges Faced

Order Management

Was PO No
Customer sends Contact customer for
Information
Purchase Order (PO) Missing information
Complete? Wait for new
PO

Yes

No
Do price No
& Qty on PO Contact management for Continue with
match quote? Further instructions new information?

Yes
Yes

Print “Material Required”

Confirm PO to Report and use the BOM to
Customer A
determine the materials
That must be ordered.
Order Management

Check inventory for Check vendor Select Vendor and Receive Materials
A
Existing stock approvals Order materials as they arrive

Inspect material for

quality

Follow Material Return

Does material No process to return the sub
conform to standard materials.
standards?
Start of production B

Update inventory Issue Work Order to Production team

for received Shop floor for draws material from
material Start of production inventory.
Order Management

Quality check on Pass quality No Sort & remove defective /

B
finished product check? sub standard materials.

Yes

Packaging

Customer
Shipment

END

Return of unused
Invoicing Accounts
Material to stores
Purchasing Module
About The
Implementation Workflow
Company

Process Benefits/
Pre-ERP time
Automation Limitations

New ERP Way Forward

Benefits
Parameters No of Days No. of Days
Pre-ERP Post-ERP

Order Released for Manufacturing 5 0

Inventory Components 70% 30%
B.O. Nxt 4 Mnth Only currnt mnt
Client Account Updating EOD,EOW Instant
Dealer, Godown Stock updation Every Week Instant
Dispatch details for Transit insurance Next Day Instant
BOM 5 days 1 Day
Del for Small GB 16-18 wks 8-10wks
Change in scheduling Not possible Flexible
Delivery Status 1-2 days Online
Limitation
 Over the time various product code entries have
created a huge code master.
 Small modification required new code & new BOM
 Communication between client, Branch,
Manufacturing cannot be documented
 Each component have relation to a drawing no.
separate data base to be maintained for drawings.
 User customizable data report not possible
 Stockiest/Dealer stock updation & order booking.
 Client cannot view the status since its VPN based.
About The
Implementation
Company

Process
Workflow
Automation

Benefits/
Pre-ERP time
Limitations

New ERP Way Forward

Way Forward
 On Demand ADHOC reports
 CRM
 Service Module
 Thank You
Eric D’Souza 103
Amit Chapekar 110
Jalinder Dighe 107
Narayan Mistry 114
Rahul shetty 125
Rashmi Shetty 126
Rahul Butani 131