Better Production Erp S O F T W A R Egear Motions Supplies High Pr ✓ Solved
â– BETTER PRODUCTION ERP S O F T W A R E Gear Motions supplies high-precision gearing to companies in numerous industries. It offers an array of precision manufacturing services that include gear grinding and cutting; turning; milling and drilling; broaching and keyseat ing; ID and OD grinding; ID honing; and inspection. ERP System Enables Gearmaker to Achieve Needed Agility EDITED BY ELI PLASKETT I ASSISTANT EDITOR COMPANY Gear Motions PROBLEM Custom ers dem anded increasingly short lead tim es SOLUTION M o du lar ERP so ftw a re from Global Shop Solutions RESULTS Im proved access to inform ation enabled the shop to im prove costing and scheduling For years, Gear Motions managed its business with an enterprise resource planning (ERP) system that lacked the ability to track data in real time.
It relied on users to manually input data in order to update the system. Because of this, changes to schedules or supplier deliveries could render it useless. Without real-time information on stock and machine space availability, the company’s ability to accurately quote potential customers suffered at a time when customer demands were increasing. Three divisions comprise western New York’s Gear Motions, which distributes its products domestically and abroad. The company’s services include gear grinding and cutting; turning; milling and drilling; broach ing and keyseating; inner diameter (ID) and outer diameter (OD) grind ing; ID honing; and inspection.
It can manufacture gears ranging from a fraction of an inch to as large as 6 feet in diameter. Providing this array of services became increasingly difficult to sched ule and cost because customers want product a lot quicker than they used to, says plant manager Dan Bartelli. Jobs that used to take eight to 10 weeks to complete are now expected in three to five weeks, he says. The time crunch provided a significant challenge to the business. Cut ting machining time in half meant that supplier delays and machine sched uling could significantly affect its ability to meet customers’ demands. » 96 M M S FEBRUARY 2019 mmsonline.com â– BETTER PRODUCTION ERP S O F T W A R E In order to m e e t in c re a s ingly tig h t d ead lin es from cu stom ers, G ear M otions had to reth in k its approach to scheduling jobs.
Eventually, the com pany s e ttled on an ERP system from Global Shop S olutions to im prove access to d ata. By bringing th is data to g e th e r in an e a s y -to -u n d e rs ta n d fo rm a t, the system e n ab les Gear M otions to be m ore a c c u ra te in costing and quoting. M aking Inform ation Accessible To remedy this, Gear Motions turned to Global Shop Solutions’ ERP system, which was able to provide accurate, up-to-date information on all aspects of the company’s operation. According to materials manager Dan Sierotnik, “Information from suppliers automatically updates, and it pulls information from different parts of the company together to make scheduling more intuitive.†Various modules comprise the software to pro vide detailed information about the shop, includ ing which jobs are in progress, who is logged into a machine, what order a user is working on and how far along a job is.
According to Suzanne Waters, director of accounting and information technology, the ERP system helps get the product out faster by providing a more global view of the shop floor. “It also helps us order and purchase ' " ' i f . _ _ L f _____ â– BURNI SHI NG THE FAS THE LEADER IN HOLE FINISHING SOLUTIONS EST, MOST ECONOMICAL WAY TO A GREAT FINISH S I Z E F I N I S H W O R K H A R D E N IN SECONDS I.D.s, O.D.s, tapers, faces and more • Eliminate costly grinding and honing • Used on a variety of m achines • W ide range o f tools available from stock Universal Burnishing Tools S h a fts , fa c e s , ta p e rs , c o n to u rs , s m a ll a n d la rg e O .D .s i y —ifrJjFB fH fritji , D iam ond Burnishing Tools O .D .s , la r g e I.D .s , o r fa c e s o f a lm o s t a n y d ia m e te r CO G SDILL visit cogsdill.com cal PO BOX 7007 C A M D E N , SC MINIS FEBRUARY 2019 mmsonline.com S c h e d u lin g an d C o sting B E TTER PR O D U C TIO N â– materials more efficiently by showing what we have in inventory, how much we need to order and the lead times for purchasing those materi als,†she says.
Further, as a modular product, the shop only needs to implement the modules that specifically speaks to its needs. One of the biggest draws for Gear Motions was the Advanced Planning and Scheduling (APS) module, which assists in scheduling jobs. “Sched uling with APS enables us to execute more effec tively because it gives detailed views from a job, department and entire shopfloor perspective,†Mr. Bartelli says. “It provides many different ways to slice and dice the data, so we can tell what we need to do and when to meet tighter shipping deadlines.†This provides the company with better information for both short- and long-term planning.
Mr. Bartelli says he feels confident in the data’s accuracy and uses it to make necessary adjustments to meet customer deadlines. “The system automatically updates the data every five minutes, so we can see exactly what’s going on in the shop in real time,†he says. “This allows us to act in the moment rather than looking at a report a month later and saying we should have done something differently.†The Supply and Demand module has also proven to be helpful. It enables the user to bring numerous pieces of data together on one screen, including work order, sales and purchase history.
By bringing this data together in an easy-to-understand format, the system enables Gear Motions to be more accurate in costing and quoting. “It gives us a very efficient quality check process to make sure we did things right and correct G ET YO UR H E A D things when we IN T H E CLO UD did not,†Ms. _. Should you move to a cloud- W a t e r s s a y s . baSed ERP system ? Learn about its benefits: gbm .m edia/e2erp R e in f o r c in g C o m p a n y C u ltu re Gear Motions uses the ERP software to create custom Crystal reports. One of these reports » E l e c t r i c S p in d le s f o r M a c h in in g C e n t e r s H ES510: 5 0,0 00 R P M MAX H ES810: 80,000 R P M M AX U LTR A H IG H S P E E D S.
S U P E R P R E C IS IO N 1 Transforms CNC Machines into High Speed Machining Centers 1 Ultra-Precision Ceramic Bearings for High Speed Performance ’ Integral Motor and Spindle Construction ' Emergency Break-Away Connector I â– 1 Air-Cooling System I 1 ft ftL â– Small Diameter Drilling and Milling & i # 2 â– Large Variety of Tapers Available IT H S K A NSK AMERICA CORPORATION 1800 Global Parkway, Hoffman Estates, IL 60192 Phone: ( I Toll Free: ( I Fax: ( [email protected] MODERN MACHINE SHOP 99 mailto: [email protected] â– BETTER PRODUCTION E R P S O F T W A R E tygriiZfh G«arOiec Global Shop S o lu tio n s’ ERP system provides d iffe re n t m odules to p erso n alize the fe a tu re s to th e shop’s needs.
Each m odule brings d iffe re n t sets of inform ation together, so a shop can pick th e best m odule to serve its shopfloor personnel w h ile selectin g other m odules fo r o th er d e p artm en ts. day. The report shows which jobs they worked on the day before, when the jobs started and ended, how many parts were completed or scrapped, and so on. It also identifies setup time, indirect time and whether they forgot to log in or out of a particular sequence, she says. Providing reliable performance data without judgment is part of maintaining a culture of feedback and openness. & tracks output for machine operators on a daily basis, providing a feedback tool for improving performance and accountability.
According to Ms. Waters, the company prints a copy of this report and gives it to all machine operators each G ear M o tio n s g e a rm o tio n s .c o m Global Shop S o lu tio n s g lo b a ls h o p s o lu tio n s .c o m Mikron Multistar CX-24 The fa ste st m a c h in in g system fo r sm all precision parts » Precise serial production of part families and demanding workpieces » ± 2.5 pm table index accuracy » Up to 44 machining units operating simultaneously at 24 stations NEW FEATURES » Compact and optimized design with better ergonomics and up to 25% less footprint » Rotating operating panel » Options and peripherals properly integrated » Multistar CX-24 CNC version with up to 20 CNC axis available M ikron Corp.
Monroe 200 Main Street - Monroe, CT 06468 / USA Tel. wvwv.youtube.com/mikrongroup III M IK R O N 100 MMS FEBRUARY 2019 mmsonline.com content may not be copied or emailed to multiple sites or posted to a listserv without the articles for individual use. â– BETTER PRODUCTION ERP S O F T W A R E Gear Motions supplies high-precision gearing to companies in numerous industries. It offers an array of precision manufacturing services that include gear grinding and cutting; turning; milling and drilling; broaching and keyseat ing; ID and OD grinding; ID honing; and inspection. ERP System Enables Gearmaker to Achieve Needed Agility EDITED BY ELI PLASKETT I ASSISTANT EDITOR COMPANY Gear Motions PROBLEM Custom ers dem anded increasingly short lead tim es SOLUTION M o du lar ERP so ftw a re from Global Shop Solutions RESULTS Im proved access to inform ation enabled the shop to im prove costing and scheduling For years, Gear Motions managed its business with an enterprise resource planning (ERP) system that lacked the ability to track data in real time.
It relied on users to manually input data in order to update the system. Because of this, changes to schedules or supplier deliveries could render it useless. Without real-time information on stock and machine space availability, the company’s ability to accurately quote potential customers suffered at a time when customer demands were increasing. Three divisions comprise western New York’s Gear Motions, which distributes its products domestically and abroad. The company’s services include gear grinding and cutting; turning; milling and drilling; broach ing and keyseating; inner diameter (ID) and outer diameter (OD) grind ing; ID honing; and inspection.
It can manufacture gears ranging from a fraction of an inch to as large as 6 feet in diameter. Providing this array of services became increasingly difficult to sched ule and cost because customers want product a lot quicker than they used to, says plant manager Dan Bartelli. Jobs that used to take eight to 10 weeks to complete are now expected in three to five weeks, he says. The time crunch provided a significant challenge to the business. Cut ting machining time in half meant that supplier delays and machine sched uling could significantly affect its ability to meet customers’ demands. » 96 M M S FEBRUARY 2019 mmsonline.com â– BETTER PRODUCTION ERP S O F T W A R E In order to m e e t in c re a s ingly tig h t d ead lin es from cu stom ers, G ear M otions had to reth in k its approach to scheduling jobs.
Eventually, the com pany s e ttled on an ERP system from Global Shop S olutions to im prove access to d ata. By bringing th is data to g e th e r in an e a s y -to -u n d e rs ta n d fo rm a t, the system e n ab les Gear M otions to be m ore a c c u ra te in costing and quoting. M aking Inform ation Accessible To remedy this, Gear Motions turned to Global Shop Solutions’ ERP system, which was able to provide accurate, up-to-date information on all aspects of the company’s operation. According to materials manager Dan Sierotnik, “Information from suppliers automatically updates, and it pulls information from different parts of the company together to make scheduling more intuitive.†Various modules comprise the software to pro vide detailed information about the shop, includ ing which jobs are in progress, who is logged into a machine, what order a user is working on and how far along a job is.
According to Suzanne Waters, director of accounting and information technology, the ERP system helps get the product out faster by providing a more global view of the shop floor. “It also helps us order and purchase ' " ' i f . _ _ L f _____ â– BURNI SHI NG THE FAS THE LEADER IN HOLE FINISHING SOLUTIONS EST, MOST ECONOMICAL WAY TO A GREAT FINISH S I Z E F I N I S H W O R K H A R D E N IN SECONDS I.D.s, O.D.s, tapers, faces and more • Eliminate costly grinding and honing • Used on a variety of m achines • W ide range o f tools available from stock Universal Burnishing Tools S h a fts , fa c e s , ta p e rs , c o n to u rs , s m a ll a n d la rg e O .D .s i y —ifrJjFB fH fritji , D iam ond Burnishing Tools O .D .s , la r g e I.D .s , o r fa c e s o f a lm o s t a n y d ia m e te r CO G SDILL visit cogsdill.com cal PO BOX 7007 C A M D E N , SC MINIS FEBRUARY 2019 mmsonline.com S c h e d u lin g an d C o sting B E TTER PR O D U C TIO N â– materials more efficiently by showing what we have in inventory, how much we need to order and the lead times for purchasing those materi als,†she says.
Further, as a modular product, the shop only needs to implement the modules that specifically speaks to its needs. One of the biggest draws for Gear Motions was the Advanced Planning and Scheduling (APS) module, which assists in scheduling jobs. “Sched uling with APS enables us to execute more effec tively because it gives detailed views from a job, department and entire shopfloor perspective,†Mr. Bartelli says. “It provides many different ways to slice and dice the data, so we can tell what we need to do and when to meet tighter shipping deadlines.†This provides the company with better information for both short- and long-term planning.
Mr. Bartelli says he feels confident in the data’s accuracy and uses it to make necessary adjustments to meet customer deadlines. “The system automatically updates the data every five minutes, so we can see exactly what’s going on in the shop in real time,†he says. “This allows us to act in the moment rather than looking at a report a month later and saying we should have done something differently.†The Supply and Demand module has also proven to be helpful. It enables the user to bring numerous pieces of data together on one screen, including work order, sales and purchase history.
By bringing this data together in an easy-to-understand format, the system enables Gear Motions to be more accurate in costing and quoting. “It gives us a very efficient quality check process to make sure we did things right and correct G ET YO UR H E A D things when we IN T H E CLO UD did not,†Ms. _. Should you move to a cloud- W a t e r s s a y s . baSed ERP system ? Learn about its benefits: gbm .m edia/e2erp R e in f o r c in g C o m p a n y C u ltu re Gear Motions uses the ERP software to create custom Crystal reports. One of these reports » E l e c t r i c S p in d le s f o r M a c h in in g C e n t e r s H ES510: 5 0,0 00 R P M MAX H ES810: 80,000 R P M M AX U LTR A H IG H S P E E D S.
S U P E R P R E C IS IO N 1 Transforms CNC Machines into High Speed Machining Centers 1 Ultra-Precision Ceramic Bearings for High Speed Performance ’ Integral Motor and Spindle Construction ' Emergency Break-Away Connector I â– 1 Air-Cooling System I 1 ft ftL â– Small Diameter Drilling and Milling & i # 2 â– Large Variety of Tapers Available IT H S K A NSK AMERICA CORPORATION 1800 Global Parkway, Hoffman Estates, IL 60192 Phone: ( I Toll Free: ( I Fax: ( [email protected] MODERN MACHINE SHOP 99 mailto: [email protected] â– BETTER PRODUCTION E R P S O F T W A R E tygriiZfh G«arOiec Global Shop S o lu tio n s’ ERP system provides d iffe re n t m odules to p erso n alize the fe a tu re s to th e shop’s needs.
Each m odule brings d iffe re n t sets of inform ation together, so a shop can pick th e best m odule to serve its shopfloor personnel w h ile selectin g other m odules fo r o th er d e p artm en ts. day. The report shows which jobs they worked on the day before, when the jobs started and ended, how many parts were completed or scrapped, and so on. It also identifies setup time, indirect time and whether they forgot to log in or out of a particular sequence, she says. Providing reliable performance data without judgment is part of maintaining a culture of feedback and openness. & tracks output for machine operators on a daily basis, providing a feedback tool for improving performance and accountability.
According to Ms. Waters, the company prints a copy of this report and gives it to all machine operators each G ear M o tio n s g e a rm o tio n s .c o m Global Shop S o lu tio n s g lo b a ls h o p s o lu tio n s .c o m Mikron Multistar CX-24 The fa ste st m a c h in in g system fo r sm all precision parts » Precise serial production of part families and demanding workpieces » ± 2.5 pm table index accuracy » Up to 44 machining units operating simultaneously at 24 stations NEW FEATURES » Compact and optimized design with better ergonomics and up to 25% less footprint » Rotating operating panel » Options and peripherals properly integrated » Multistar CX-24 CNC version with up to 20 CNC axis available M ikron Corp. Monroe 200 Main Street - Monroe, CT 06468 / USA Tel. wvwv.youtube.com/mikrongroup III M IK R O N 100 MMS FEBRUARY 2019 mmsonline.com content may not be copied or emailed to multiple sites or posted to a listserv without the articles for individual use.
Paper for above instructions
Better Production ERP System Implementation for Gear MotionsIntroduction
The manufacturing landscape is evolving rapidly, with heightened customer expectations for quality, speed, and efficiency. In light of these changes, Gear Motions, a provider of high-precision gearing solutions, faced significant challenges in fulfilling customer demands for shorter lead times. With its existing enterprise resource planning (ERP) system relying on manual data inputs, Gear Motions struggled to maintain real-time visibility into its operations, resulting in inefficiencies in costing, scheduling, and resource management. To address these issues, Gear Motions adopted a modular ERP system from Global Shop Solutions, facilitating improved data accessibility and operational agility. This paper discusses the challenges faced by Gear Motions, the implementation of the ERP system, and the resulting benefits while highlighting the importance of ERP systems in today’s manufacturing environment.
Identifying Challenges
Gear Motions' previous ERP system lacked real-time tracking capabilities, which hindered its ability to provide accurate quotes and meet customer deadlines. The reliance on manual inputs led to inconsistencies in data and inefficiencies in the scheduling process. Plant manager Dan Bartelli noted that jobs that previously took eight to ten weeks were now expected within three to five weeks, intensifying the need for a more responsive approach to scheduling and costing (Plaskett, 2019). This situation underscored the importance of an ERP system that could integrate data across the various divisions and functions of the organization, enabling more effective decision-making.
Key challenges included:
1. Inefficient Scheduling: The inability to manage schedules effectively meant that delays were frequent, leading to customer dissatisfaction.
2. Poor Data Visibility: Manual data entry created information silos that hindered collaboration and transparency within the organization.
3. Inaccurate Costing: The lack of real-time information impeded the company’s ability to generate accurate cost estimates, which is critical for profitable pricing strategies.
Implementing the ERP Solution
To overcome these challenges, Gear Motions opted for the ERP solution from Global Shop Solutions. The modular nature of the software allowed for implementation tailored to the specific needs of the organization (Plaskett, 2019). By integrating various functions such as manufacturing, accounting, and supply chain management, Gear Motions was able to streamline operations.
Key Features of the ERP System
1. Real-Time Data Updates: The system automatically updates data every five minutes, allowing the company to track jobs and performance metrics in real-time (Plaskett, 2019). This feature has dramatically improved operational transparency and responsiveness.
2. Advanced Planning and Scheduling (APS): The APS module enhances scheduling capabilities, giving detailed views from various perspectives—job, department, and shop floor level. This feature allowed Gear Motions to optimize resource allocation and prioritize urgent jobs effectively (Plaskett, 2019).
3. Supply and Demand Module: This module provides a consolidated view of sales and purchase history, enabling more precise inventory management and reducing excess stock (Plaskett, 2019).
4. Crystal Reports: Gear Motions utilized the ERP system's reporting capabilities to generate customized Crystal reports that track machine operators' performance daily, facilitating accountability and continuous improvement efforts (Plaskett, 2019).
Results of Implementation
The implementation of the Global Shop Solutions ERP system has led to significant improvements for Gear Motions in various areas:
1. Enhanced Costing and Quoting: With improved access to accurate and up-to-date information, the company can generate quotes and costing estimates much more effectively, ensuring profitability while meeting customer expectations (Plaskett, 2019).
2. Increased Operational Efficiency: Real-time data visibility has allowed Gear Motions to streamline its production processes, reducing lead times and ensuring timely delivery. Scheduling has become more intuitive, with data available for informed decision-making on resource allocation and job prioritization.
3. Improved Customer Satisfaction: The enhanced ability to meet tighter deadlines has resulted in increased customer satisfaction, as the company can fulfill orders more rapidly and with greater reliability (Plaskett, 2019).
4. Cultural Reinforcement: The organization’s use of reliable performance data has fostered a culture of feedback and openness. By providing performance metrics to machine operators, Gear Motions encourages accountability and dedication to quality and efficiency (Plaskett, 2019).
Conclusion
The introduction of a modular ERP system from Global Shop Solutions has positioned Gear Motions to adapt effectively to market demands. By addressing the challenges of real-time data visibility, efficient scheduling, and precise costing, Gear Motions can now respond to customer requirements more effectively, marking a significant transformation in its operational capabilities. The success of this initiative underscores the vital role ERP systems play in modern manufacturing, facilitating improved coordination, resource management, and customer service.
References
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