Industrial Manufacturing & EPC

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, KPI, 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 molds 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 in various clients. 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.

The solution vision slide illustrates the business processes of Industrial Manufacturing and EPC that are automated and integrated through various business applications, including ERP, CRM, POS, Distribution Management Systems, and apps. This integration aims to provide the organization with a seamless control and decision-support system.

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

Below are the sub-industries and domains found within an industrial manufacturing and EPC company, including the typical core processes followed within this industry. The core consists of some products from our industrial manufacturing and EPC clients.

Acxiom Steel, Metals & Component Industry Experience

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.