The Cablex Group (Slovenia, Germany, Poland, and Turkey) was looking for a solution that would establish more accurate control over their production based on their specific production processes. Group companies had been already been using the ERP solution (Navision and later Axapta) for managing the material operation and production, planning products and production processes, planning the production on the macro level and managing inputs from production realization (termination).
4 key 'challenges' of Cablex enterprise
A rigid system that didn't support all of the specifics
Product planning (production bills of materials) and production processes (technological processes) were first supported in the ERP system. Despite some adaptations, management using this system was awkward. Furthermore, the system didn't allow installation of certain production specifics which could let the company use its own know-how of production processes, which is a huge advantage over their competitors.
Product planning was not transparent
Product planning on the macro level was supported by the ERP system, but didn't allow entry of Cablex specific features in the production bill of materials, product procedures and production processes.
Instructions went through several channels
Workers on the production line received their instructions on every product in the specific production phase only partially and in paper form, namely partly through the ERP system and partly through other systems. Entry of data for realization was supported by the ERP system, although it was not possible to enter realization for separate production phases.
The system didn’t allow automatic upgrades
During the project of transferring the ERP system from Navision Manufacturing into Axapta, Cablex discovered that add-ons and special features that were updated in the old system could not be automatically updated, but had to be implemented again into the new system.
What was the solution that we developed at Agito?
Cablex decided on a solution 'Support of technology and production' which we developed at Agito and which represents the perfect solution for planning and tracking the production, while also allowing for expansion and enhanced opportunities that are adapted to the specific needs of the production businesses.
At Cablex they use the ERP system to support the business system which maintains the general data required for operation of the financial-accountancy work, material operations, storage etc.
Support of technology and production
The system stores additional data that is linked exclusively to the specifics of the production of Cablex and is not required by the ERP system. The solution enables graphical editing of cutting and wiring schemas (product plans) with all specifics and details which are transferred into ERP upon confirmation as production bills of materials. Furthermore, graphic editing of the technologic processes is supported by all the special features and details which are transferred into ERP as assembly plan. It is possible to work with product data, parameters and attributes, documents, tools, standard functions, jobs, as well as various code-lists. Events of the product life cycles and product processes are also included.
Planning modules
The system enables automatic and manual actuation of the last published working orders from the ERP system. Users see such transferred operations of working orders as pending operations that are planned as single work capacities. A graphic browser enables simple filtering, grouping and sorting of operations with regard to different categories in which it uses the features adapted to the production process used in Cablex, which optimizes planning. Planning also allows all progressive actions of dividing and uniting, deleting and restoring, finishing and re-planning of operations and working orders. Moreover, the system provides modules that define capacities schedules, reserved capacities, capacity material needs, as well as unforeseen stoppages and missing material.
Web interface that records realization of each production phase
The web interface supports a production specific display of instructions for operations on the production line, including all the necessary details. Realization input is possible for each respective production phase and supports input for a single operation, namely per product or standard working order task, including confirmation of automatically gathered data entries from machines, as well as for the entire work order product. Input also supports printing intermediate, packaging and wrapping labels depending on the data contained in the respective work order, with its corresponding bar code. All data on realization and packaging is automatically transferred into the ERP system for further use, where the production process concludes with signing off on material, finalizing work orders, dispatching etc.
5 main benefits that Cablex has from our partnership
Lower operation and production material costs
Higher productivity of production processes
Raising the level of internal process realization
Greater transparency over
- existing plans of products and their production processes,
- state of completed production and work in progress,
- current and planned capacities utilization.
An open and upgradeable system that enables
- integration with other systems,
- subsequent implementation of analytical systems,
- electronic assignment of operations across production machines,
- direct link with time registration and manufacturing.