Configured for Success

Key benefits Product sales configuration now much faster, automated and error free Waste reduced on the shopfloor due to automated manufacturing verification Global operations 24/7 through integrated e-business system Automated Working Time Directive management Better business decision making through accurate costing and status data Foundation for guiding and achieving business and manufacturing improvement targets Bury St Edmonds-based, sensors and transmitters maker Amot, which turns over £14m, is reaping the reward of a top-to-bottom manufacturing ERP implementation that is dealing with its need for mass customisation, while also managing the shopfloor and providing supply chain e-business support. Amot chose a Syspro ERP system from McGuffie Brunton, and it’s a good example of a company not falling into the trap of simply replicating what it already had in its ageing legacy minicomputer system, but taking advantage of modern technology. Why McGuffie? “We wanted a standard system that could provide at least the integrated functionality we had, but was flexible enough to be configured to our manufacturing and operational requirements,” says Amot’s IT Manager Jason Turrell. “We also wanted a PC-based system, and one that could be operated on a Terminal Server Network, so that we could keep central administration but give everyone a graphical user interface.” Amot also liked its newer functionality, like the product configurator and Equator HR suite. Turrell indicates there have been several improvement opportunities, some subtle, some more radical. At the easy end has been running MRP much faster and getting better business data more quickly. “While hardly in the ‘wow’ category, such improvements are significant in helping to improve decision making, which in turn will lead to helping us reach our improvement targets.” Then there’s been Syspro’s HR suite, covering payroll, personnel, time and attendance (T&A) and shopfloor data collection. That replaced a dedicated system, but again offers subtle advantages, like automatic Working Time Directive analysis. Advanced SFDC terminals also provide easier and accurate data collection through barcode scanning, along with more accurate job costing data and activity analysis. However, McGuffie’s product configurator is an example of new technology making major improvements. Turrell: “Our products, especially valves, switches and sensors, have become increasingly complex. We needed to find a more effective way to manage the front-end business processes, from enquiry and sales order through to shopfloor control.” The old way was the classic paper chase of technical documentation and pricing structure guides. Now, sales work through questions posed by the configurator, directly with customers. It automatically determines valid options, determines lead times, standard cost and price, along with a quote by applying volume, value break and customer discounts. If the order is placed, it creates a detailed sales order, also establishing the product code, which cross references to drawings, and converts that to a works order and product BoM and routing in Syspro – with all relevant information is transferred to the shopfloor. “The sales configuration process is now quicker, less confusing and error prone, and this is saving time and effort on both the part of our sales staff, and the customers. We are also avoiding wasted time, effort and materials on the shopfloor, as there are now far fewer ‘problem’ orders being accepted.” But there will be more when Amot completes its planned e-commerce strategy for key distributors, which involves direct access to its ERP through a virtual private network (VPN). “As well as being a relatively cost effective approach, the VPN offers Amot many benefits,” says Turrell. “Whilst an e-commerce enabled website and web application programs can offer controlled links into an ERP business system, they only provide limited access. Whereas, through the VPN the distributors will achieve full access. “This means that as well as easily reviewing information on order progress, delivery dates and accounts information, distributors will be able to use the configurator directly, to establish product quotes and generate their own sales orders and works orders. We believe this offers the potential to radically improve customer service. It will also help reduce the support levels needed internally.”