CASESTUDY

Roadmap ERP
Inks the Best Solution
for the Digital Concerns of
Pen Manufacturing Companies

Roadmap IT Solutions (P) Ltd.

No. 5, Republic Street | Reddiarpalayam |
Pondicherry - 605 010 | India

Phone: +91 413 4207 333

India | Middle East | Africa

R

www.roadmapit.com mktg@roadmapit.com
Integrate Innovate Succeed
 Brief Company Pro le
e Pen Manufacturing Company was established during the mid-1990s and
is located in Karnataka, India. e company is powered by its tip
manufacturing facility and tool room, which has the capacity to design,
develop and manufacture molds. Presently the company has the capacity to
manufacture 0.5 million mechanical pencils and 1 million Ball Pens and is one
of the largest exporters of pens and mechanical pencils in India. e entire
production of the company is exported.

Brief Company Pro le

e Pen Manufacturer has a state of the art Tool room equipped with CNC machines, CNC Sparking machines;
super drilling machine and other machining facilities that provide high precision mold components for Injection
Pen/Mechanical Pencils Molds. e organization has around 80 injection molding machines and automated
assembly machines that are capable of producing over 50 million parts, which can be assembled to manufacture
millions of Ball pens, Gel Pens and Mechanical pencils.

e company follows Failure Mode and E ects Analysis (FMEA) process and Production Part Approval Process
(PPAP) to ascertain the manufacturing of good quality products. To enhance its Production mechanism and to
maintain high quality standards, the company has an online monitoring system, LAN with call escalation, built in
Vision system / Poke Yoke in injection molding and assembly machines, FIFO system for WIP and Finished Goods,
Preventive and Conditional based maintenance system, process control approach, and a well-equipped quality
testing Lab. To ensure employee safety and skills development, the organization adheres to environment and
personnel safety standards and provides training and continuous improvement programs.

Reason to Choose Roadmap

e company had Excel and & Manual Registers to handle data transactions & reports, and there was no
codification for items. e Pen manufacturer has many products and di erent colors, so it could not
monitor the stock transaction in the following processes:
Inventory Control & Stock Transactions
Quality Control
System Generated Reports
Monitoring Stores Activities
Production Related Issues
Bill of materials for all products
 Reason to Choose Roadmap
Other aspects that compelled the organization to go for an ERP were:
To avoid the existing Excel & Manual Data registers
To maintain the class & subclass
To systemize the existing oral communication in stores consumptions
To avoid the production of more items than in the orders
To generate systematic reports through ERP
To identify the estimated mold life in injection molding
To monitor machine idle times
To generate machine History

To rule out the pain points thus experienced, the company realized the need for an e ective ERP solution
and called for suitors. Of all the ERP solutions that responded to the Organization's call, it found Roadmap
ERP to be the technologically and economically best-fit system with the most amicable answers to address
each one of its pain points.

The Pen Manufacturer's Pain Points Addressed by Roadmap ERP

Inventory Control & Stock Transactions

e Pen Manufacturer maintained SKUs "Store Keeping Unit" for its Fgs.
e company could not check the stocks at di erent stages of Production like injection molding item, printing
item, assembled item & SKU (FG).
In all process, they could not check the QC & monitor the stock color-wise & product-wise.

Roadmap ERP captures Machine, Tool, Shifts, and Mold details, and enables the easy monitoring of
tool life and stock transactions at multiple stages easily.
Roadmap created item codi cation for all items and also categorized the items like RM, SFG, and FG.
e ERP provides the scope to check the QC and to monitor the stock color-wise & product-wise.

Quality Control
e Company used manual register & manual report for Quality checking process.

Roadmap con gured the inspection plans for Incoming QC, Line QC, Final
Inspection, and Pre-dispatch Inspection. Based on the plans the items and its
characteristics & speci cation are inspected and appropriates entries are made.
Once the entries are done, the corresponding report against the plan is generated.
Monitoring Stores Activities:
e Organization did not maintain Material Request/Material Issuance in the system, so there was a constant
mismatch in the raw materials & consumables transactions.

Based on the Production order, the Material Request and Material Issuance data are tracked by the Roadmap ERP
system against each and every Production Order and Job Work. is ensures the maintenance of Stores in a Uniform
Structure, and especially, by reducing the unwanted Cost.

System Generated Reports

e Pen Manufacturer maintained only manual registers and reports and required systematic reports in all
areas.

In all the modules furnished by Roadmap, the ERP captures the existing reports format and provides system
generated reports for PO, Sales invoices, Packing List, Job Orders, Material Request Slip, Material Issuance Report,
Stock Reports, etc.

Production Related Issues

Production users produced more items compared to orders.
Runner/Raiser wastages were not monitored.
More consumption for production.
Roadmap ERP addressed all these issues and also helped better the existing system through the provision of the
following facilities:
e ERP provides the scope to manufacture both on a make to
order or make to stock modes.
MRP1 - Material Requirement Planning -Based on the
Customer PO, the system runs MRP and releases the PO's and
Job Orders.
MRP2 - Material Resource Planning - Based on the MRP1, the
ERP runs the Resource planning including manpower.
Other Process Entries - Based on the Production Order the
so ware schedules manpower and machine-power entries in
the ERP, and enables the tracking of each and every entry for a
Single Production Order, so that the Production Order for each
and every Sales Order can be tracked.
Production Order - e solution aids the input of Production
Entries based on the Sales Order, and ensures the eradication of
unwanted Cost by facilitating the tracking of the cost of
Production Entries against the Sales Order.
 Tool Life and Machine History - e Process monitors the entire history of the Machine and Tools and enables the
concerned stakeholders to clearly view the cost of operating the machinery and have a complete idea of
machine/tool idle/working time against every Production Order.
Production Wastages - By finding the runners & raisers wastages against all injection molding transactions the
system reduces wastages to a great level.
Bill Of Materials for all products:
e company did not have a Bill of Materials for all products.

Roadmap ERP creates Bill of Material for all Products and accurately defines the input material for each production
order.
Roadmap ERP enables GST compliant inputs and outputs for Purchase, Sales and Finance oriented transactions of
the Pen Manufacturer.

Implementation Success

Roadmap, through its Business Process Re-engineering (BPR) approach, understood the needs
and purposes of the Concern's business processes. Roadmap's BPR experts effectively collaborated
with the Organization's core-team and succeeded in implementing the ERP on-time.

e comprehensive integration of Roadmap full-suite ERP with the entire business process of the
Pen Manufacturing Company has eased its management by integrating all its functional units from
within and without. Roadmap ERP solution provides accurate details to precisely plan the
procurement and production processes. Further, it empowers the Stakeholders to make faster and
better management decisions by providing crucial information in a timely manner. e ERP has
ultimately delivered high ROI by totally solving all the snags that were pulling the company behind
from functioning smoothly.
 e comprehensive integration of Roadmap full-suite ERP
with the entire business process of the Pen Manufacturing
Company has eased its management by integrating all its
functional units from within and without. Roadmap ERP
solution provides accurate details to precisely plan the
procurement and production processes. Further, it
empowers the Stakeholders to make faster and better
management decisions by providing crucial information in
a timely manner. e ERP has ultimately delivered high
ROI by totally solving all the snags that were pulling the
company behind from functioning smoothly.

Integrate Innovate Succeed

Roadmap IT Solutions (P) Ltd.

No. 5, Republic Street | Reddiyarpalayam | Pondicherry - 605 010 | India
Phone: +91 413 420 7333
Email: mktg@roadmapit.com
Corporate Operational Of ice : Pramuk Aqua Heights, Flat# C-602, 6th Floor, C Block,Electronic City Phase I, Hosur Main Road, Veerasandra Village, Bengaluru 560 100.
Ph: +91 9972319933
Regional Of ice-Chennai : II loor, No.43/46,Brindavan Street Extension, West Mambalam,Chennai-600 033, India.. Ph : +91 94425 10123
Regional Of ice-Coimbatore : Old.No.20, New No.39,Vinayagar Koil Street,1st Floor, Krishnasamy Nagar, Ramanathapuram, Coimbatore - 641 045, India. Ph:+91 94425 80742
Regional Of ice-Pune : A/13, Erica, Magarpatta, Hadapsar -411013, Pune, Maharashtra, India. Ph :020-26898155, 91722 62949
Regional Of ice-Vadodara : 23, Upper Ground Floor, Silver Rock Complex , Bhavan's School Circle , Vadodara - 390004 , Gujarat, India. Ph : +91 8300 637 127
Overseas Of ice Middle East : Zaitunah Commercial Center , Of ice Suit # 205; Bld No.7097, Jeddah-23343-3523, KSA. Tele/Fax: +966 12 6133817
Africa : 7 Troon Cresent, Silver Lake Golf Estate, Pretoria, South Africa. Ph: +27 61 080 7322.