Manufacturing ERP Software Buyers Guide

JobBOSS. Shop management solutions. MANUFACTURING ERP SOFTWAR E BUYERS GUIDE A guide to selecting the right shop management system. jobboss.com 2 MANUFACTURING ERP SOFTWARE BUYERS GUIDE What is shop management software? Manufacturing shop management software is designed to increase efficiency and productivity in the office and on the shop floor. It contributes to key business initiatives by tracking detailed information such as status of quotes and orders, inventory levels, on-time delivery performance, employee efficiency, and work center capacity planning. Business owners and shop floor managers use shop management software every day to keep their fingers on the pulse of production activity by having instant access to all aspects of the manufacturing process. Order changes, work-in-progress management and scheduling conflicts are easily accessible when shop management software is used to provide visibility into all shop floor activity. In essence, shop management software allows you to quote, process, track and cost orders, manage material and outside services, enable real-time labor tracking and efficiency reporting, schedule production, and support your entire business with an integrated accounting solution - all within an atmosphere of constant change. CHOOSING THE RIGHT MANUFACTURING ERP (ENTERPRISE RESOURCE PLANNING) SYSTEM ISN’T EASY This Buyers Guide will assist you in objectively assessing ERP vendors and selecting the right solution for your business today and wherever it takes you in the future. MANUFACTURING ERP SOFTWARE > Make-to-stock > Assemble-to-order > Make-to-order > Mixed-Mode MANUFACTURING ERP SOFTWARE BUYERS GUIDE 3 Quoting Can your system quote multiple quantities and automatically calculate pricing for new parts without the need for a part/estimation or engineering master? Does your system have the ability to quickly regenerate quotes on part history of similar parts by allowing for the ability to copy from previous jobs or work orders? Can your system easily transfer a quote directly to a job? Processing the order Can your system handle quick-run jobs, blanket orders, complex assemblies, time and material jobs and split jobs? Can your system easily make changes when a job is in process? Can your system generate a shop traveler automatically with all job requirements? Business reason: Custom, make-to-order, make-to-stock, assemble- to-order and mixed mode manufacturers need a system which streamlines the quoting process and reduces the steps necessary to create quotes for new work. Extra steps in the quoting process increases the time required to respond to customer RFQs and may hinder your ability to respond in a timely manner and win new work. Business reason: Visibility to previous cycle times for similar parts is critical to re-quoting work that is similar. Up-to-date part history at your fingertips allows your company to instantly respond to customer requests to quote similar parts. Business reason: Creating work orders or jobs to manufacturer a part is essential to reducing the time from receipt of order to release to the shop floor. Efficient work order/job release is imperative to shipping on time. Eliminating duplicate data entry is key. Business reason: Job shops and custom manufacturers are known for their ability to respond quickly to customer requirements. For many shops, no two jobs are alike. The ability to generate different types of work orders and easily split orders is imperative to increasing your ability to respond to changing customer requests. Business reason: The ability to make changes (with minimal effort) when a job is in process supports your ability to quickly respond to customer change requests. It can mean the difference between shipping on time and losing future work because your shop cannot respond quickly enough. Business reason: Generating a shop traveler is key to manufacturing the part correctly the first time. It provides all of the information about the part in one consolidated packet with the ability to link the latest part documentation including the latest revision of the part right to the job. It will reduce the cost of rework and scrap. SAMPLE QUESTIONS TO ASK SOFTWARE VENDORS The following are actual questions from real RFPs submitted to JobBOSS by manufacturers considering JobBOSS 4 MANUFACTURING ERP SOFTWARE BUYERS GUIDE Scheduling the job Can your system schedule by a job’s due date, material availability, or work center capacity and globally reschedule all jobs based on actual job results? Can your system easily let you view shop loads vs. capacity? Can your system generate dispatch reports and isolate jobs running late? Can your system automatically schedule material purchases and outside series to a job’s operation requirements? Labor reporting Does your system log all employee direct, indirect and overtime hours against jobs? Does your system easily track scrap and rework and reason codes? Can your system evaluate employee performance? Material control Does your system provide full inventory management for raw stock, hardware, supplies and finished goods? Does your system provide you with time- phased material planning based on purchase orders and work orders? Can your system provide the flexibility to either buy materials direct to a job or to stock? Can you view purchase history and stock levels online with your system? Business reason: Effective and flexible scheduling that can account for material availability, current work center load, and actual job performance when re-generating a schedule is crucial. Business reason: This eliminates running your shop purely based “on your gut” or intuition. It allows you to quickly isolate bottlenecks or see available holes in the schedule where you can slot in more work. Business reason: It reduces the time lost in the schedule not knowing what to work on next. In addition, it can help to isolate jobs running behind or running late so the shop foreman can react before it is too late and while there is time to rectify the problem. Business reason: It can help your shop reduce the cost of carrying excess material as a safety buffer and increases the efficiency of those who need to create purchase orders and is critical to lean material management. Business reason: It’s pretty simple. Direct hours make you money and indirect/overtime hours could lose you money. Shop owners and managers are often tasked with reducing direct to indirect labor. Having a system that allows you quick visibility to direct, indirect and overtime hours can help you better manage this key business indicator. Business reason: Reducing scrap and rework is a key lean initiative and directly contributes to overall company profitability. Business reason: Knowing which employees are most efficient doing different types of work is critical to company profitability. Visibility to inefficient employees allows you to also develop employee training programs targeting specific reasons for that inefficiency. Business reason:How a shop manages raw material and the visibility of different sizes of the same type of raw stock is critical and can help to eliminate excess purchasing. Business reason: Managing your purchase of material to when it will be consumed will typically save a shop 30-70% in additional carrying costs. Business reason: Visibility to commonly consumed material to consolidate material purchases may in the end save you significant dollars. Having a flexible system that allows you the visibility of both direct buy material and inventory purchases is critical to take advantage of these cost savings. Business reason: Visibility to material requirements, purchase history, and current stock levels allows you to better manage your material levels, reduce expedite charges, and track those vendors who provide you material at the best price on a consistently on-time basis. MANUFACTURING ERP SOFTWARE BUYERS GUIDE 5 Shop view, shop stats, shop alerts Does your system have an executive dashboard that shows current business information and activities? Can you view customer, production, vendor, and financial, statistics and data in one place? As events and changes occur, can your system send pop-up alerts and instant messages via email, mobile phone or pager? Shipping the order Does your system let you stay on top of upcoming deliveries with delivery and backlog reports? Can your system handle over-shipments and under-shipments? Can your system track customer returns? Can your system generate pack lists with documentation to the customer? Can your system analyze delivery performance to improve on-time deliveries? Analyze costs Does your system let you know what every job, with the ability to compare estimated to actual labor, material and outside service costs? Can your system isolate problem jobs while in process? Can your system keep part history for repeat jobs? Business reason: CShop owners don’t have time to wait for data or even to run a lot of reports every day to know the overall health of the business. Visibility to those key business indicators that quickly provide insight into which areas of the business are running well and those areas that are not allows you to focus your energy on the areas which need your attention. Business reason: Customer, vendor, production and financial performance are the key areas that directly impact a shop’s profitability. Business reason: Automatic notification increases awareness of job status and can identify areas for improvement. Business reason: Knowing which orders need to ship is critical for maintaining the on-time delivery performance required by your customers. Business reason: Customers are constantly changing their delivery requirements—sometimes right up until you ship. Business reason: A key quality indicator for every shop is the number of parts your customer returns. How you deal with the parts and rectify the problem quickly and easily once they arrive is critical to managing and maintaining customer satisfaction. Business reason: Customer shipping requirements are as unique as the customer. An incorrect pack list or shipping document could lead to a return or a reject based on incorrect documentation and a delay in invoicing and payment. Business reason: On-time delivery performance is still a critical metric for whether your customer awards you more work in the future. Business reason: Because every job (sometime even for the same part) may yield different results depending on who worked on the job or the cost of material or outside service, it is critical to be able to review actuals to estimates on each job and isolate those issues so they are not consistently repeated. Business reason: Visibility to projected costs before a job gets out of control is imperative to managing a profitable manufacturing business. Business reason: Online part history quickly aids in re-quoting a part (or similar parts) and allows for quick analysis of part cost and profitability trends. 6 MANUFACTURING ERP SOFTWARE BUYERS GUIDE Customer Relationship Management (CRM) Can your system organize and simplify the process of managing customer relationships? Can your system identify top customers and see pipeline quotes? Can your system record customer conversations, set follow-ups and manage activities? Automated workf low Can your system automate your business process from quote to cash? Can your system immediately improve efficiency, accountability, and compliance? Does your system allow me to gain visibility and control of my processes both within and outside of manufacturing? Total Quality Management (TQM) Can your system manage my quality related business processes? Does your system meet ISO9000, Six Sigma, and other unique industry and vendor- specific regulatory requirements? Integrate beyond job control Can your system integrate with the following applications? SolidWorks Microsoft Excel, Word, Access, SQL QuickBooks UPS WorldShip Business reason: This helps maintain alignment between all the aspects of the business including estimating, customer service, and sales. Business reason: Visibility to most profitable and most “growable” customers is the foundation for current profitability. Nurturing new potential customers helps to ensure future growth. Business reason: Insight into every customer interaction ensures activities are coordinated and correct expectations are set with the customer. Business reason: One of the reasons shop management systems are so widely adopted is because of the ability to automate current processes in order to streamline, adjust and improve communication internally and with customers. Business reason: Shop management software that enforces standard business workflows offers immediate results and increased accountability. Business reason: Business issues may arise beyond the scope of manufacturing and the shop floor. Visibility and control of these business processes through automated workflows assures everyone is on task and focused on those priorities which are critical to business success. Business reason: Total Quality Management helps to reduce risk through visibility and control of quality issues throughout the manufacturing process. Business reason: Your customers are requiring compliance to ISO, AS9100, FDA, and other industry quality initiatives. A quality management system integrated with your shop floor system provides your company seamless control and management of these compliance and risk initiatives. Business reason: Manufacturers today utilize different solutions to control unique aspects of their business. Your shop floor management solution should seamlessly integrate with these applications to reduce data entry errors, reduce duplication of effort and increase efficiency. MANUFACTURING ERP SOFTWARE BUYERS GUIDE 7 Pricing,implementation, service & support Can you prove full transparency of pricing and any additional costs that may be incurred from implementing a shop management solution, including but not limited to, training, support, etc.? Do you provide a dedicated customer advocate and training program to help go live? Do you have an online support and best practices center? Can other product users contribute? Is it monitored by a staff member? Please provide a typical timeline for implementation? Can you provide details of any available, optional services that your company provides? How frequently does your company have new product releases and how is training done on new features and functionality? Business reason: Transparency of pricing means shop owners/ managers can budget more effectively and won’t be surprised with unexpected costs after the initial sale. Business reason: A dedicated customer advocate aids in short implementation time, meaning shop owners/managers can get up and running quickly for fast results. Business reason: A valuable web self-service area is essential to getting the most out of the product, accessing helpful resources, and interacting with experts and customers. Business reason: The faster you implement shop management software, the faster you can achieve ROI on your purchase. Business reason: Services will help you make the most of your shop management tool when moving past the basics, or when you need business process help. Business reason: Shop management software is an evolving technology. Your company should be able to take advantage of all features of the shop management solution and be communicated regularly via multiple communication options, such as email, phone, customer portal posting, etc. Every shop management system demo will be a little different. Regardless of the path the salesperson takes, make sure the system you select makes you feel confident about these seven critical areas. WHAT TO LOOK FOR IN A MANUFACTURING ERP DEMO 1) I can easily create customer quotes, enter orders, track labor, manage outside services, and track material costs with this integrated solution. 2) I have all the functionality I need today, but still have plenty of room for growth. 3) This system will give me visibility to which types of orders make money and which ones do not. 4) My employees will be able to improve their efficiency and be more accountable. 5) My customers will see improved on-time delivery performance and improved product quality because of this system. 6) I saw ways to automate my shop’s manual processes, reduce duplicate data entry and felt confident this system provides the structure and control to manage my business. 7) I have options for both cloud and on-premise software, and can choose the right solution for my business. MANUFACTURING ERP SOFTWARE BUYERS GUIDE 9 REMOTE HOSTED VS. ON-PREMISE SOFTWARE The use of hosted or cloud software is showing strong and consistent growth. Cloud computing – an umbrella term for a wide range of online services – is an attractive option for small and medium sized businesses (SMB) manufacturers seeking to make the most of current technology at lower costs and lower risk. With a low-cost monthly subscription and hosted software, the upfront investment in software / hardware and low, licensing and renewal costs are kept to a minimum. SMB manufacturers are often faced with the dilemma whether they should go for a hosted or an on-premise solution. There is really no right or wrong answer but companies need to assess their business needs and infrastructure before taking a decision. There are advantages and disadvantages with both platforms. The quick reference guide below outlines the pros and cons of both hosted and on-premise delivery models. Platform Benefits On-Premise Software Hosted Software / Subscription Buy vs. Subscribe You own the software. One-time, up-front payment plus annual maintenance fee Flexible monthly subscriptions. Ongoing monthly payments with maintenance included Cost Lowest total cost of ownership Lowest monthly cost Payment Purchase with 30-90 day terms Automated credit card billing TCO Lowest total cost of ownership Lowest initial cost of ownership User Model Concurrent seat licensing Implementation Implementation takes time and planning No hardware or software installation. Hosted on the cloud Hardware You own and maintain hardware and IT systems Any internet able device Security Your IT staff monitors data security and back-ups Data security and back up ensured by vendor User Access Software installed on every PC Web browser Connectivity You are responsible for internet connectivity and your company intranet for integration with: - Non-hosted/SaaS software utilized on premise (i.e. Office, nesting, CAD) - Hardware utilized for business operations (i.e. printers, labelers) IT Operations and Maintenance Running and updating the system is in your hands No need to maintain the system, vendor handles updates and enhancements Scalability Easily add seat licenses Easily add seat licenses Balance Sheet A depreciable capital expense Not a capital expense Accessibility Connectivity to the intranet is determined by the company Accessible 24/7. For use on many devices, anywhere, anytime