Industrial
Manufacturing & EPC
The uniqueness of industrial manufacturing lies in the use of heavy machinery and high power and fuel consumption for the production process. This results in a sharp focus on operational costs, capital investment, power fuel usage, and efficient capacity management. Segments such as industrial chemicals, steel, automotive components, paper mills, sugar plants, cement plants, and specialty metal casting fall under this categorization.
Another distinctive aspect is the critical use of dyes and moulds in industrial manufacturing, which are part of capacity and material planning. Our journey began with a prominent steel company for which we developed a customized ERP. We later upgraded the same company to Navision and then to Axapta 2012. One of our most complex solutions for that client was integrated planning, covering container export of white bar, backward production planning of gold bar, and casting integration. This project provided a strong foundation of knowledge in industrial manufacturing and was implemented for various clients in several projects. Similar processes are observed in steel, heavy industries, and EPC. EPC involves managing production cycles as a project, including integrated production, erection, commissioning, and post-commissioning warranty and AMC cycles.
We have implemented solutions across the following matrix of products, sub-industry, and core business processes for the Industrial Manufacturing business.
End Consumer
Sales & Dealer Portals
&
Mobile Apps
• Loyalty Ledger
• Dealer Portal
• Schemes, Discounts, Rebates
• Events
• Sales Alerts
• Launch Notifications
• Personalised Broadcasts
Brand Website
Marketplaces
Online Channels
Institution
Corporate
B 2 B Channels
Dealer
Retailer
Modern Trade
Distribution Channels
- Primary Sales
- Secondary Sales Tertiary
- Sales
- Schemes Discounts & Settlements
- Fleet Management
- Warehousing (Hub-Spoke)
- C&F
- Exports
- Consignees
- Replenishment
- Min/Max, Buffer Stock
- Multisite Routing
Omni Channel
Management
Designing
- Ground Up
- Top Down
- Sales Forecasting
- Sales Targets
Design & Manufacturing
- BOM
- ECN
- Quality
- Capacity
- Material Planning
Sourcing
- Vendor Empanelment
- Delivery Schedules
- Procure to Pay
Warehouse Management
- Blocking/unblocking.
- Reservation
- Picking & Packing
- Replenishment
- Cycle counting
- Receiving
- RF Support
- Mobile devices
- Waves
Project, Service & Asset Mgmt.
- CAPEX
- Product Design
- Research & Development
- Time and Action Contrai
- Warranty
- AMC
- Project Plan
- Tasks
- Timelines
- Owner
- Delegation
- Escalation
HR Management
- (Hire to Retire)
- Recruitment Process
- Performance Management
- Balanced Scorecard
- Payroll, Leave, Expense
- Skills
- Roles
- KPIs
Management Accounting
- Trading Vs Manufacturing
- Brand Vs Brand
- Region Vs Region
- Budgeting & Control
- Profit Center Acct.
- Cost Accounting
Treasury Management
- Fund Flow
- Cash Row
- Dollar & Currencies
- Hedging & Risk Management
- Bond and Investments
- Debt & Equity
Statuary Management
- Trial Balance
- Balance Sheet
- Fixed Asset Mgmt
- Inventory Valuation
- GST
- Statutory Retums
- TOS
Vendor Portal
&
Mobile
Apps
• Sales Portal
• Dealer Portal
• Schemes, Discounts, Rebates
• Events
• Sales Alerts
• Launch Notifications
• Email and SMS Broadcasts
• Sales Targets v/s Actuals
• Ledger Reconciliations
Business Intelligence & Data Warehousing
Our Experience in Steel, Metals & Component Industry
Products: Sponge Iron, Sponge Iron DRCLO, MS Billet, Iron Beam, Channel, Angle, Flanges, Rings, Tower Flanges, Steel Blinds, Tube Sheets, Shafts, Forged Discs, Gear Blanks, Galvanized Pipes, ERW Pipes, CDW Pipes, Fledges, Solar Equipment's, Railway Bridges parts, TMT Bars, Angles, Black Bars, Billets, Ingots, Bright Bars, Angles, Flats, Wire Rods, Hexagons, Hammer, Jaw plate, Concave, Blow bars
Processes: Smelting, DRI(Direct Reduction Iron), SMS(Steel Melting process), CCM(Continuous Casting Machine), Rolling Mill, Hammer Forging, Press Forging, Machining Process, Pickling, Slitting, Mother Hollow Rolling, Cold Drawing(Single / Multiple Passes), Annealing, Heat Treatment, Straightening, Rolling, Electric Melting, Refining, Casting–Ingot, Casting–Continuous, Rolling, Heat Treatment, Cold Finishing, Cold Drawing, Packing Allocation–Deallocation, Moulding, Fatling
Casting
- Consolidation of grades as per SalesOrder/Demand Forecast
- Optimization quantity to heat size of 25MT
- Consideration of leftover material + Material rejected in different processes
Rolling
- Auto Consolidation of sizes in-order to reduce change over time
- Prioritization of Rolling Plan as per Customer off take schedule
Finishing Process
- Sequencing of different machining processes as per Route Card
- Grouping of the same size and grade material asper machine setting
Common
- Allocation De Allocation– Heat details are defined as Item attributes. If Heat attributes match with the Customer TDC attributes then only allocation will be done else the system will not allow the allocation process. In the deallocation process reserved inventory is moved to open status.
- Batch Card Closure– If input quantity is equal to Output quantity then only system will allow batch card closure for inventory matching.
- Mechanical & Metallurgical Parameters– If parameters does not match with test parameters defined in the TDC system will not pass the lot in QA inspection.
- Test Certificate Generation- The test certificate is autogenerated & sent to the customer when the material is shipped to the customer.
Pharmacy
- UID wise planning
- Shipment Planning
- Plant Capacity Planning
- Slitting Plan
Unique Process
- Multiple UOM(MT / LBS, Meter / Ft & Pcs / number)
- Customer TC
- TDC Creation
- Consolidation of Chemistry Parameters
- Metallurgical & Mechanical Test Parameters in Quality
- Allocation of Multiple Standards
- Unique Item Creation on the basis of Item Attributes