Highlights of OPTI.kompakt: Planning • Integrated operations schedule and parts list as a continuous resources plan • Simple, fast and exact to the last cent cal- culation of all manufacturing steps • Takes just minutes to enter a new part by duplicating and adapting resources plans • Similarity search • Integrated materials database • Provides enquiries with schedules while ta- king the complete schedule chain into ac- count • Automatic material requirements analysis • Workflow and release-controlled interdepart- mental work Production • Displays all manual and mechanical mould processes • Automatic scheduling across all manufactu- ring steps taking capacities and bottlenecks into account (MRP II-run) • Flexible, scalable feedback chains in pro- duction • Procedure-controlled administration of all tools and patterns for moulds and cores • Integrated test planning and certificate ge- neration • Detailed planning for each day or shift using add-ons • Seamless links between foundry-specific modules ensure synchronised processes Reporting/GIS • Integrated web-based GIS, (Foundry Infor- mation System) – continuous information system about all data relevant for the pro- duct and production • Management information for decision-ma- kers • Comprehensive standard reports and real time evaluations • Visual planning using the utilization and ca- pacity cockpit • Open database Compact price Complete coverage Unrivalled performance Medium-sized foundries have special requirements for their corporate soft- ware. OPTI.kompakt provides you with an optimised FRP system (Foundry Resource Planning) specially tailored to the needs of small and medium-sized foundries with 5 or more workstations. Every foundry is special. The OPTI.kom- pakt modular principle makes it possible to adapt it flexibly to your requirements. From detailed planning, service planning, claims and knowledge management through to in- tegrated charge calculations – we deliver a whole range of modular solutions. This also means that OPTI.kompakt can grow with your company. In addition to its informative and easy to operate user interface, OPTI. kompakt is convincing on so many levels, with its simple handling, comprehensive displays and the fact that it integrates typi- cal foundry processes. All of this is provided at an unbeatable price combined with short implementation times. More than 30 years of experience and process structures from more than 100 foundries have gone into our FRP system. OPTI.kompakt consolidates our developments in a pre-configured standard solution. Combine this with our consultants’ ex- pertise and you will soon notice that you have not just bought a software solution, you have also gained a long term success- oriented partner for your company. We live and breathe casting and struc- turing your processes - Know-how Cast in Software. THE COMPACT FRP SOLUTION OPTI . KOMPAKT
RGU_OPTI-kompakt
Dec 14, 2015
Do you think existing ERP (Enterprise Resource Planning) not suitable to
meet the requirement of the foundries? Why? What could be the solution?
ERP is not the new term for most of the foundryman. ERP was introduced with
the main intention to handle large data of manufacturing. Existing ERP
fulfills the requirement of foundries? Probably not because today the
biggest requirement of foundry is "Single system used by all the departments
of foundry" as most ERP does not include many vital operation/flow/process
of foundries.
Does your ERP include Tool-Pattern management, production planning, Core
production, shift planning, Record material composition from Spectrometer
for each heat, Historical data of each quality test? - Probably most of the
ERP does not include this.
Can there be any solution? - RGU GmbH, Germany has been developing FRP -
Foundry Resource Planning think beyond ERP. Dedicated FRP system developed
only for foundries not applicable for other manufacturing process other than
foundry. Over 120 foundries across pan Europe are running successfully on
RGU-FRP software since last 30 years.
Limitations of the existing ERP:
1) How to calculate cost of casting part or total production/day:
If you are Foundry owner or top level management, the biggest challenge
would be, to calculate the CTC (cost to the company) for a single part or
cost of total production/day etc. Most of the foundries never know this
cost exactly, because foundry deals with so many possibilities, and
nonlinear flow of process which are not part of the existing ERP. To
calculate this foundries should consider design & simulation cost, tool
management, rejection, scrap, energy cost, slag, material cost variations,
labor cost, unplanned activities (machining, external machining/services or
surface improvement), underutilization of man or machine, idle machine time
and cost, return circuit etc. Any solution? - RGU.OPTI - FRP software read
below.
2) Resource planning
Most of the ERP system cannot do the fully resource planning, because it
does not have modules for production planning, Fettling & machining, quality
check/test. If the foundry is able to specify each the resources required
for their casting part, and if ERP allows to record all the required
resources in the system, the remaining job would be very easy for foundries
to order, track, store, use and dispatch the required resources. But if ERP
does not integrate with production, tool room, quality it would be
impossible to streamline your resource planning, and despite use of ERP it
increases burden of lots of work, email communication or miscommunication,
paper work despite using the technology. Can any ERP software do complete
resource planning even for new order booked? - YES IT IS POSSIBLE with
RGU.OPTI - FRP software read below.
3) Tool management
Tool & pattern management is one of the biggest need of foundry which is
missing in most ERP. For any production planning concern person should know
availability of tool, mould box, or die casting machine. Tool & pattern
manufacturing, required time for making, cost, maintenance time and cost
etc. If ERP does not included this how could one calculate exact cost of
part or total life cycle of tool cost? Can any ERP system includes
tool-pattern management? - YES IT IS POSSIBLE with RGU.OPTI - FRP software
read below.
4) Design & Simulation data
Foundries do various trial and error, or try possible ideas of various
gating system design for which they have various drawings for each trial, 3D
CAD model, Casting simulation data, if it is not recorded on ERP how would
you consider required time, effort and cost to develop one part? And even in
future when similar part , it would be very easy for foundries to see the
various design they have done in past and calculate cost and required time
based on past history saved. Does any ERP really in
meet the requirement of the foundries? Why? What could be the solution?
ERP is not the new term for most of the foundryman. ERP was introduced with
the main intention to handle large data of manufacturing. Existing ERP
fulfills the requirement of foundries? Probably not because today the
biggest requirement of foundry is "Single system used by all the departments
of foundry" as most ERP does not include many vital operation/flow/process
of foundries.
Does your ERP include Tool-Pattern management, production planning, Core
production, shift planning, Record material composition from Spectrometer
for each heat, Historical data of each quality test? - Probably most of the
ERP does not include this.
Can there be any solution? - RGU GmbH, Germany has been developing FRP -
Foundry Resource Planning think beyond ERP. Dedicated FRP system developed
only for foundries not applicable for other manufacturing process other than
foundry. Over 120 foundries across pan Europe are running successfully on
RGU-FRP software since last 30 years.
Limitations of the existing ERP:
1) How to calculate cost of casting part or total production/day:
If you are Foundry owner or top level management, the biggest challenge
would be, to calculate the CTC (cost to the company) for a single part or
cost of total production/day etc. Most of the foundries never know this
cost exactly, because foundry deals with so many possibilities, and
nonlinear flow of process which are not part of the existing ERP. To
calculate this foundries should consider design & simulation cost, tool
management, rejection, scrap, energy cost, slag, material cost variations,
labor cost, unplanned activities (machining, external machining/services or
surface improvement), underutilization of man or machine, idle machine time
and cost, return circuit etc. Any solution? - RGU.OPTI - FRP software read
below.
2) Resource planning
Most of the ERP system cannot do the fully resource planning, because it
does not have modules for production planning, Fettling & machining, quality
check/test. If the foundry is able to specify each the resources required
for their casting part, and if ERP allows to record all the required
resources in the system, the remaining job would be very easy for foundries
to order, track, store, use and dispatch the required resources. But if ERP
does not integrate with production, tool room, quality it would be
impossible to streamline your resource planning, and despite use of ERP it
increases burden of lots of work, email communication or miscommunication,
paper work despite using the technology. Can any ERP software do complete
resource planning even for new order booked? - YES IT IS POSSIBLE with
RGU.OPTI - FRP software read below.
3) Tool management
Tool & pattern management is one of the biggest need of foundry which is
missing in most ERP. For any production planning concern person should know
availability of tool, mould box, or die casting machine. Tool & pattern
manufacturing, required time for making, cost, maintenance time and cost
etc. If ERP does not included this how could one calculate exact cost of
part or total life cycle of tool cost? Can any ERP system includes
tool-pattern management? - YES IT IS POSSIBLE with RGU.OPTI - FRP software
read below.
4) Design & Simulation data
Foundries do various trial and error, or try possible ideas of various
gating system design for which they have various drawings for each trial, 3D
CAD model, Casting simulation data, if it is not recorded on ERP how would
you consider required time, effort and cost to develop one part? And even in
future when similar part , it would be very easy for foundries to see the
various design they have done in past and calculate cost and required time
based on past history saved. Does any ERP really in
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Highlights of OPTI.kompakt:
Planning• Integratedoperationsscheduleandparts
listasacontinuousresourcesplan• Simple,fastandexacttothelastcentcal-
culationofallmanufacturingsteps• Takesjustminutestoenteranewpartby
duplicatingandadaptingresourcesplans• Similaritysearch• Integratedmaterialsdatabase• Providesenquirieswithscheduleswhileta-
kingthecompleteschedulechainintoac-count
• Automaticmaterialrequirementsanalysis• Workflowandrelease-controlledinterdepart-
mentalwork
Production• Displaysallmanualandmechanicalmould
processes• Automaticschedulingacrossallmanufactu-
ringstepstakingcapacitiesandbottlenecksintoaccount(MRPII-run)
• Flexible,scalablefeedbackchainsinpro-duction
• Procedure-controlledadministrationofalltoolsandpatternsformouldsandcores
• Integratedtestplanningandcertificatege-neration
• Detailedplanningforeachdayorshiftusingadd-ons
• Seamlesslinksbetweenfoundry-specificmodulesensuresynchronisedprocesses
Reporting/GIS•Integratedweb-basedGIS,(FoundryInfor-
mationSystem)–continuousinformationsystemaboutalldatarelevantforthepro-ductandproduction
•Managementinformationfordecision-ma-kers
•Comprehensivestandardreportsandrealtimeevaluations
•Visualplanningusingtheutilizationandca-pacitycockpit
•Opendatabase
Compact price Complete coverageUnrivalled performance
Medium-sized foundries have special requirements for their corporate soft-ware. OPTI.kompakt provides youwith anoptimised FRP system (Foundry ResourcePlanning)speciallytailoredtotheneedsofsmallandmedium-sizedfoundrieswith5ormoreworkstations.
Every foundry is special. TheOPTI.kom-paktmodularprinciplemakesitpossibletoadaptitflexiblytoyourrequirements.Fromdetailedplanning,serviceplanning,claimsandknowledgemanagementthroughtoin-tegratedchargecalculations–wedeliverawholerangeofmodularsolutions.Thisalsomeans that OPTI.kompakt can grow withyourcompany.Inadditiontoitsinformativeand easy to operate user interface, OPTI.kompakt is convincing on so many levels,with its simple handling, comprehensive
displaysandthefactthatitintegratestypi-calfoundryprocesses.Allofthisisprovidedatanunbeatablepricecombinedwithshortimplementationtimes.
More than 30 years of experience and process structures from more than 100 foundries have gone into our FRP system. OPTI.kompakt consolidates ourdevelopmentsinapre-configuredstandardsolution.
Combine this with our consultants’ ex-pertise and you will soon notice that youhave not just bought a software solution,youhavealsogainedalongtermsuccess-orientedpartnerforyourcompany.
We live and breathe casting and struc-turing your processes - Know-how Cast in Software.
THE COMPACT FRP SOLUTION
OPTI.kOMPAkT
The core functions of OPTI.kompakt:
Planning & CalculationIntegrated resources plan:OPTI.kompakt is fully aligned to thewayfoundries reallywork.That iswhy, incontrast toother systems,wedonotconsiderworkschedulesandparts listsseparately.Alloftheresources needed for themanufacture of a particular cast part aredisplayed within a tree structure in a multi-step resources plan. Itdoesn’tmatterwhetheritconcernsself-producedcomponents(cores,patterns,melt),purchased items(filters, feeders,sand)orworkpro-cesses(pattern,clean,finish,internallyorexternally).ThelogicoftheresourcesplanisintegratedthroughoutalllevelsofOPTI.kompakt.
• Simpletocreatenewpartsandvariants• Fast,reliablecalculationofallorspecificlevelstakingall
possiblecostsintoaccountatthetouchofabutton,includingpurchasedpartsandexternalservices
• Similaritysearchesforarticlesalreadycalculated• Calculationsarchive• Administrationofalltechnicalparametersinthepartsmaster• Integrated,comprehensivematerialsdatabase,withsaveable
testplans
SalesThesalessectionguaranteesreliableandclearcreationofoffers,or-derprocessing,dispatchorganisationandinvoicing.
• Ittakesjustafewdaysfromreceivinganenquirytosendingouttheoffer
• Supportforalltypesoforder,suchassampleandfirstsample,individual,seriesandmakeandtakeordersforproductsaswellasforpatternsandtools
• Savesallcustomeragreements,awidevarietyofMTZandETZmodels,allmetalpricelistswithallcolumnsandtherelevantvalues(LME,VAWetc).Allsurchargescanbesavedspecificallyaccordingtocustomers,parts,materialsorprocesses.
• Problem-freeadaptationwithinflationincreasesandautomaticinformationtothecustomeraboutpricechanges
• Displaysawiderangeoflogisticsprinciplessuchaspreview,fixedorders,consignmentstockorcommercialgoods
• Seamlessinteractionbetweentheproductionandcontrolplan-ning:fastfeedbackregardingcustomer’spreferreddates
PurchasingInthepurchasingmoduleyoucanorganiseyourcompany’sprocure-mentactivitiesclearlyandefficiently.Alltheinformationwhichisnee-dedbythepurchaseraboutsuppliersandpurchasedarticlesissavedin the master data and linked with storage/consumption and priceunitsaswell asa varietyofparameters for controllingprocurementandtechnicalspecifications.
• Administrationofallthedifferenttypesoforderdetailssuchasframeworkorders,individualorders,manualandautomatedordertracking
• Detailedpricesheetfunctionwithpriceconditionssuchasamounts,discounttables,deliveryconditionsandmetalprice-lists
• Materialrequirements,purchasedpartsandexternalservicesarerecordedaccordingtoordersorgeneratedautomaticallyasaccumulatedweeklyamountsortheycanberecordedmanually
• Takesintoaccountminimumavailablestockrequirements,orderlotsizes,replacementtimesandtheorderswhichhavealreadybeentriggeredOverviewprovidedatanearlystageinordertooptimiseorderquantitiesfromthepointofviewofcostsandliquidity
• Integratedreminderanddunningprocessforsuppliers.
Production and control planningThePPS-Systemistherightinstrumentfortheoperationalandstrate-gicplanningofyourproduction.WiththePPS-System,theschedulingandcapacitysituationcanbecontrolledandmonitoredquicklyandre-liablyfortheshortandlongtermandforallschedulinglevelsandbot-tlenecks.ThePPS-Systemshows itsparticularstrengths inplanningandsynchronisingmould,meltandcastingprocesses.Thedifferenttypesofcontinuousanddiscontinuousprocessescanbesynchronisedforthedifferenttypesoffoundryandavailabilitiesandcapacitiescanbechecked:
Allresourcesataglance:TheresourceplanistheessentialtoolforFRP. Foudry-specificbilloftools:Releasestatus,usage-listandlifecycle
RGU & Auto Design Online–Yourpartnerforconsultingandprogramminginthefoundryindustry.
• Toolavailability,preparationandprovisioningoftools,mouldingboxandpitavailability
• Coordinatesthemouldingshopandcoreproduction,ifnecessa-rytakingintoaccountthepatternboardandcoreboxavailabilityandcombinations,provisionofliquidmeltforseveralmouldingshopareasandmaterialqualities,ifnecessaryformationofcastingbatches
• Takesaccountoftherequiredcooldownandholdingtimes• Processandcapacity-utilizationforfinishingcastparts,ifneces-
sarywithexternalservices• Formationofheattreatmentbatches• Integrateddetailedplanningwithfilterfunctionsasanadd-on• Simpletosetupsensiblefeedbackchainsforseamlesstracea-
bility• Providesfoundryworkerswithinformationviatheintegrated
foundryinformationsystemwithchecklistfunctions,particularlyforcriticalwork-steps
• Automaticallygeneratescomprehensivedocumentation
ThePPS-Systemcoverstheneedsofalltypesoffoundries,fortypicalseries producers as well as for discrete producers. It is possible toaccessthelatestvalidproductionplansonlineortotransferthemtotheproductionmanagementsystems,e.g.inmouldingplants,soastocontroloperationsinthecontrolcentre.
Materials managementThematerialsmanagementsectionprovidesthesolutionforefficientstockmanagementforallproductsandprimaryproducts,purchasedorstoredmaterialsincludingloadcarriers,containers,palletsetc.withdifferentinventoryaccounts.
• Plants,locations,quarantinestore,externalserviceproviders,consignmentstore,intermediatestore,dispatchstore
• Incomingandoutgoingbookings,inventoryandstockevalua-tionsderivedfromproductioninformationmessages
• Evaluatessemi-finishedandfinishedstock• Itemmanagement,articlescanbemanagedviaIDandbatch
numbersasinventory• Permanentinventoryviaoperationalsequencestatements• Variousevaluationproceduresforinventory
Pattern management / tool management• Patternmanagementcomprisingallthetoolsneededinthe
productionandtheirvariants(diecastingtools,patternboards,coretools,moulds,CNCtools,inspectionequipmentetc.)
• Displayscomplexpatternstructuresandalltechnicalparame-tersintheresourcesplan(withpatternpartslistandtoolcard)
• Monitorstool-life,numberofcastingsandmaintenanceintervals• Alltoolprocessesrecorded,(fittingtimes,repairs,provisioning,
cleaning,dispatchetc.)• Monitorstoolavailability(castinglimitexceededduringproduc-
tion,toolisbeingservicedetc.)• Createsseamlesslifecyclereports• Recordsandstoresdocuments(drawings,photos,Officefiles)• Toolamortisation• Releaseprocedure/blockingprocedure
Comprehensive information system and evaluations• Comprehensive,web-basedinformationsystem,accessiblefrom
allmasks• Integratedfoundryinformationsystemcoveringalllevels• Proactivemanagementinformation,automaticallyfreshonyour
desk• KPI–performancefiguresforallsensitiveareas• Workflow-components• Checkliststoaccompanyprocesses• Foundryworker’sinformationcockpit
»With OPTI.kompakt we have now got costs and production under control. Our expectations have been more
than fulfilled.«
Stephan Buchholz,ManagingDirector,Buchholz&Cie.GiessereiGmbH
OrderTracking:Exampleforworkflow-orientedprocesses Schedulingmonitor:essentialtoolforthescheduler
RGU GmbH
Karl-Harr-Straße1
44263Dortmund
Fon+49 (0) 2 31.4 19 97 0
Fax+49 (0) 2 31.4 19 97 99
www.rgu.de
ww
w.b
eier
konz
eptio
n.deAbout RGU GmbH
Since1984RGUGmbHhas been develo-ping standard technical and commercialsoftwaresolutionstosupportbusinesspro-cessesefficiently.
Based inDortmund, this company is spe-cialised in providing complete solutionspackages covering everything needed forproduction planning and control systemsin foundries and the metal processing in-dustry.
The result is corporate processes whichare structured so efficiently that businesssuccesscanbeplannedfor.
Thisisachievedbymeansofcooperation,preciseanalysisandskilledconsultingser-viceswhichtakeupthecustomer’sspecificrequirementsandputthemintopractice.
After more than 30 years in the IT sec-tor,RGUhasgrown tobecomeoneof theleading providers of innovative softwaretechnologiesforPPSsystemsinGermany.Throughout Europe more than 120 custo-mers now rely on PPS and FRP solutionsfromthisDortmundsoftwarecompany.
Other services from RGUThe fact that our products focus on thefoundryindustryisnocoincidence.Workingoneveryimplementationwehaveastrongteam of consultants who have their rootsinthefoundryindustry.Thatiswhywearealsoastrongpartneratyoursidewhen itcomes to providing product-independentadvice, for structuring foundry processesor when creating specification cataloguesfor introducingsoftwaresystemsinfound-ries.We know what we, and you, are talkingabout.
What does FRP stand for?FRP is derived from ERP, the well-knownabbreviation forEnterpriseResourcePlan-ning. Instead of looking at the often un-clearlydefined“enterprise”wefocussolelyon foundries, which have significantly dif-ferent processes from those described instandard ERP systems – and that is whywehavecalleditFRP–FoundryResourcePlanning.
We would be delighted to tell you moreabout OPTI.kompakt in person and lookforwardtoreceivingyourenquiry.
Orfindoutmoreontheinternetat.:www.rgu.de
Auto Design Online 212,ArpanComplex
Nizampura,vadodara
Gujarat,India
Phone:0265-2786774
Mobile:+91-9824247774
www.auto-design-online.com
Related Documents
