Fast implementation in a make-to-order process manufacturing operation

Fast implementation in a make-to-order process manufacturing operation

The business had previously been a division of a large multi-national company that had deployed the BPCS ERP system on IBM hardware. When the division was acquired by our client they had twenty working days to transfer data from BPCS and implement a new system. With two legal entities, four manufacturing sites and more than two hundred staff this provided a significant challenge.

Sub systems covered

  • Accounting and distribution
  • Component and Sub-assembly inventory management
  • Finished Goods management
  • Costing
  • Product formulation
  • Base Product reporting
  • Supplier Price list management
  • Manufacturing Alternative formulation

Challenge:

The implementation of the new system had to take over from the current accounting system and then absorb the other roles and do that within 20 working days.

Most important of them was management of Customer Price lists – which changed to follow competitor activity, new products and seasonal response.

Change Management

Very few spare hands to assist with the installation of the new system.

Solution:

The solution included a number of the components of Adaxa Suite.

Adaxa installed and converted all the data from their existing accounting system, BPCS, into the replacement ERP system and extended the functionality to provide for the integration of a number of existing external systems.

Services Provided

  • Business Process Analysis
  • Data Migration
  • Accounting assistance
  • Modification to the user interface
  • Development of custom reports
  • Implementation and end-user training

Result:

The system was delivered within the specified time frame and the client was able to operate the essential business processes to enable them to continue to operate their business effectively. The benefits achieved were:

  • Lower acquisition and operational costs than using proprietary software
  • Lower costs associated with in-house enhancements compared with waiting for subsequent software releases
  • Better control over functional areas
  • Centralised financial operations and transactional records
Franchise Control Systems adopts ADempiere to manage its rapidly growing list of franchisees

Franchise Control Systems adopts ADempiere to manage its rapidly growing list of franchisees

Franchise Control Systems (FCS) operate a business that distributes various products through a network of franchisees. All products sold by the franchisees are sourced from the franchisor. The system performs the Enterprise Resource Planning (ERP) and Customer Relationship Management (CRM) requirements for both the franchisor and the franchisee.

The business was expanding rapidly both in terms of the types franchises operated and also in the countries and languages in which it operated.

FCS was an existing user of Compiere when ADAXA became involved with their needs and various minor modifications and improvements were performed over some months. FCS decided that modifications and improvements required in the drop-shipment capability were significant and that it would therefore be worthwhile to migrate from Compiere to ADempiere in the process of developing the drop-ship functional improvements.

ADAXA designed and implemented the improvements in drop-ship functionality and developed some extensions to the counter documents functionality that automated the sales and supply processes between the customer, the franchisee, the franchisor and the externally owned/managed warehouse. FCS contributed the enhancements back to the ADempiere community for incorporation into the core product.

Portfolio Link:

Learn more about Franchise Control Systems by visiting their website

Challenge:

FCS operates a multi-national business which has to satisfy the requirements of its franchisees no matter where they are located. This led to a number of challenges as follows:

  • The system needed to allow the operator to work in the language of their choice whilst producing documents in the recipients language of choice
  • Franchisees needed to be able to view their own data whilst the franchisor needed to be able to view the total operations
  • The system needed to accommodate the possibility of explosive growth and change of system focus due to planned expansion
  • The sales and supply processes between the customer, the franchisee and the franchisor needed to be automated to the fullst extent possible
  • Integration with externally owned warehouse(s) to effect deliveries on behalf of the franchisor
  • Enable franchisees to operate their own webstore that is fully integrated with the franchisor’s systems

Solution:

ADAXA offered a solution to migrate the Client’s current ERP system from Compiere to ADempiere and to extend the system to incorporate the Client’s broader functional requirements as described above.

Services Provided by ADAXA

  • Data migration from Compiere to ADempiere
  • Functional customizations to automate the franchisee/franchisor interaction based on the ADempiere counter document functionality
  • Ongoing support

Result:

FCS was able to expand its business into non English speaking parts of the world and provide its franchisees with improved customer service by offering improvements in operational efficiencies.

  • Integration of processes linking sale and supply transactions throughout the end user/franchisee/franchisor transaction train
  • Removed the vendor lock-in to Compiere’s data migration processes by implementing ADempiere
  • Reduction in operational costs by using the web client functionality without having to purchase a Compiere proprietary software licence
VOIP Service Provider converts from Compiere to ADempiere Open Source ERP to eliminate costly licence fees and gain improved functionality

VOIP Service Provider converts from Compiere to ADempiere Open Source ERP to eliminate costly licence fees and gain improved functionality

IP Systems operates a business providing VOIP services and distributing various related products. They have complex data capture requirements relating to the usage of the VOIP system. This data is required to generate sales transactions in the ERP system that handles all financial functions for the client. The business is expanding rapidly.

IP Systems required a system that:

  • Had the ability to be modified and extended to allow the client’s core metering systems to be integrated with the ERP system
  • Demonstrated substantial improvements in the speed of financial reporting
  • Used a fully open source technology stack that eliminated their concerns about vendor lock-in

Portfolio Link:

Learn more about IP Systems by visiting their website

Challenge:

IP Systems has been a long-term user of Compiere and Oracle XE but had decided to migrate to Postgres because this database is now in general use in the organisation for other core business processes.

The client migrated from Compiere to ADempiere to allow for use of standard Postgres (rather than the proprietary Enterprise DB version of Postgres) and also because of concerns about Compiere’s increasing use of proprietary style licences and reduced emphasis on open source.

Challenges:

  • Migration of data structures from Compiere to ADempiere
  • Migrating data from Oracle XE to Postgres
  • Financial Reporting customisations in ADempiere

Solution:

ADAXA was able to demonstrate that it had the expertise to migrate the Client’s ERP system from Compiere, using Oracle XE, to ADempiere, using Postgres, and make consequential improvements in the speed of financial reporting.

Services Provided by ADAXA:

  • Data migration from Compiere to Adempiere
  • Data migration from Oracle XE to Postgres
  • Financial reporting improvements

Result:

The successful conversion of a long standing Compiere user to ADempiere provided significant performance improvements and the move to a complete open source product set with the consequent elimination of vendor lock-in.

  • Conversion of core financials to the company’s preferred database technology
  • Removed vendor lock-in to Compiere support agreement and data migration processes by implementing Adempiere
  • Ability to use web client functionality without having to purchase a Compiere proprietary software licence
  • Ability to migrate to later versions of the ERP software without requirement to have a paid support agreement with Compiere Inc.
Intouch Direct deploys an Open Source stack to meet their complex distribution requirements

Intouch Direct deploys an Open Source stack to meet their complex distribution requirements

When Intouch Direct needed to replace their legacy business management systems they evaluated a number of popular proprietary and open source ERP systems. When it came down to cost of ownership and the flexibility they required to meet their complex needs they chose the open source alternative.

ITD’s sales activities are performed by a sixty person call center and an e-commerce website. The majority of transactions are Business to Consumer (B2C) although there is also a significant Business to Business (B2B) component. ITD’s warehousing and shipment activities are outsourced to a third party organization.

Portfolio Link:

Visit the Intouch Direct website

Challenge:

The business has expanded rapidly and its existing ERP system no longer satisfied their needs. A new system had to satisfy the following requirements

  • provide rich ERP functional capability
  • provide a content management system that incorporates a shopping cart integrated with the ERP system
  • provide the ability to modify the system without jeopardizing the ability to upgrade to new software releases
  • provide an automated exchange of electronic transactions between the ERP system and the third-party warehouse

Solution:

Intouch Direct considered a range of options and selected a pure open source solution composed of:

  • ADempiere ERP & CRM
  • Drupal Content Management and Ubercart e_Commerce System
  • Red Hat Linux
  • Postgres Database
  • Pentaho Business Intelligence
  • Asterisk Telephony

The ERP/CMS and Website selection was heavily influenced by the flexibility and ease of customizing the open source components. A specialized “Call” window was developed which provided a central point for the management of customer requests. The call center operator selects the nature of the call and the window dynamically changes to enable the entry of data relevant to the nature of the call.

The elements of a rules engine were developed to enable Intouch Direct to implement campaigns for new clients without the need to modify the ERP and webstore every time a new campaign was introduced.

The Intouch Direct website was developed using Drupal allowing the user to enter content using familiar WYSIWYG tools. Information required by the online shopping cart (e.g customers, products, orders, price lists, images. etc.) is stored in the ERP system. Business rules exist only in the ERP system and new or changed rules implemented for Call Center transactions are automatically applied in equivalent web transactions.

Data migration from the legacy system was complex and volumes were quite significant and it was necessary to ensure that the data migration process was repeatable. Graphical Open Source Extract, Transform and Load (ETL) tools were used to develop the migration scripts. Business rules required the importation of a number of years of sales history to enable the new application to determination of remaining/current entitlements under government schemes.

Result:

Intouch Direct gained a number of significant benefits:

  • Ability to introduce new campaigns without the need for system redevelopment
  • Automatic validation/management of complex business rules relating to third party campaigns
  • Fully integrated Content management System and webstore
  • Facility to allow authorized carers/health professionals to act on behalf of their clients
  • Reduction of training costs resulting from the simplified call center functionality
  • Automation of data exchange with third party logistics provider
Complex customer processes automated

Complex customer processes automated

Complex custom processes requiring multiple levels of unit conversions and highly specialized shipping are successfully automated in this case study you can read here.

PRO® (a division of BAF Industries) needed to replace their disparate DOS based systems with an integrated and automated way to take their complex chemical formulations from raw materials and manufacture through to shipping and delivery.

 

 PRO® (a division of BAF Industries), develops, manufactures, and distributes professional car care products. The PRO® Distributor Network has more than 300 distributors in the U.S. and internationally.  PRO® is headquartered in Santa Ana, California, and has another facility in Florence, Kentucky

 

Portfolio Link:

Learn more about BAF/PRO by visiting their website

Challenge:

 

PRO® has a very complex manufacturing process involving intricate chemical formulations. Maintaining efficient inventory levels is vital to profitability. Additionally, shipping chemical products domestically and internationally requires the production of detailed shipping documentation

 

PRO® needed a system to:

  • Manage unit of measurement conversions in the production process for accurate and effective costing.
  • Provide real-time views of inventory for efficient purchasing.
  • Automate the generation of appropriate shipping documents, such as Material Safety Data Sheets, for a variety of chemical products.
  • Improve inter-site communication between the California and Kentucky locations.

Solution:

The Adaxa team offered the solution by providing:

  • Data migration from a legacy system to ADempiere.
  • Insightful business analysis of PRO®s business requirements, for a best-fit system.
  • Substantial system customizations, made cost effective by using open source technology.
  • Unified software integrating both PRO® locations.

Result:

PRO® received a highly customized, open source system without paying the high cost of proprietary system licensing fees.

Other benefits are:

  • Increased efficiency in production, maintained inventory levels, purchasing and shipping.
  • Expansion of operations in the Kentucky facility.
  • Potential for future growth from a stable system platform.
Publishing company automates complex accounting.

Publishing company automates complex accounting.

First run publications have additional costs and accounting complexities that are unique to the publishing industry.

First run publications have additional costs and accounting complexities that are unique to the publishing industry. When printing a book a significant cost is in the setup of the highly sophsticated printing machinery, so the first runs incur higher costs than subsequent runs. The accounting becomes very complex and time consuming. With Adaxa Suite, they were able to sucessfully automate the associated publishing.

Maintaining integrity with the handling of royalties is also a critical aspect of a publishing company’s business and Adaxa was able to improve and enhance this process.

Challenge:

First run publications incur all the setup and publishing costs that are not found in subsequent runs. The challenge was to automate the existing laborious manual task of associating actual costs derived from work in progress to the correct General Ledger accounts for these first run publications.

The second challenge was to accurately calculate, record and disperse royalties in a timely and efficient manner while insuring compliance throughout the whole process.

Of importance was the ability to maintain the integrity of all operating systems and procedures while transferring from the old system architecture to the new more robust and flexible Adaxa Suite ERP.

Solution:

Adaxa provided a highly configurable, feature-rich and flexible ERP system which enabled the automation of multiple cumbersome manual processes.

Result:

Royalties are now able to be accurately recorded and dispersed in a much more timely manner and are able to be easily tracked; the result saving almost two person-months of labor.

Accounting processes are streamlined and automated and accurate financial reporting is available at all stages of print runs.

Testimonial:

This publishing house is currently publishing 120 titles each year while continuing to offer over 800 additional titles from previous years.