INFORMATION TRENDS IN MANUFACTURINGThe Need for Enterprise Resources ManagementA WHITE PAPER by Richard N. Stover
Richard
N. Stover is Chairman and Principal Consultant of (www.ermdm.com),
a strategic analysis firm. He can be reached at 480-585-5580 or email:
ermdm@aol.com
INFORMATION
TRENDS IN MANUFACTURING The
Need for Enterprise Resources Management A
WHITE PAPER by Richard N. Stover
Observing the
marketing hype over the last five years invokes the question, what does it all mean and
where is it leading? Imaging, Workflow, Document Management, EDM, PDM, ERP, Supply Chain
Management, Customer Relationship Management, Knowledge Management! Youve
undoubtedly heard one or more of these terms used as the latest and greatest, the
end-all of your information needs! No wonder that executives of user companies are
confused. Add to this the continually changing platform environments, i.e., Internet,
Intranet, Microsoft, Java, Thick Clients, Thin Clients, etc., and you have to think that
chaos is the only solution. I believe that there is a logical solution that involves all
of these technologies to meet the Number One
Executive Challenge: HOW TO
TRANSITION FROM TOTAL ANALOG (MANUAL) INFORMATION... TO TOTAL
DIGITAL (ELECTRONIC) INFORMATION... WHILE
MAINTAINING THE STABILITY OF YOUR DAILY OPERATIONS...! Each
technology can provide limited functionality in reaching the overall goal of total
electronic commerce for the enterprise. Finding the right combinations of these
technologies for your organization is the only way to survive in todays business
environment. Lets put each of these technologies in the proper context for
management: 1. Imaging - The electronic
backbone to handling all legacy paper- and microfilm-based information. This involves
scanning the manual documents and converting them to (pixel-based) images in standardized,
compressed formats. Your organization may have already converted some or all of your
documents and may have an Imaging System(s) already installed. That Imaging
System probably includes scanning, storage and some image retrieval capabilities that can
be integrated with additional technologies. The issues of
Imaging include: ¨ Which
documents to scan-convert? Use an as-needed basis versus archived document groups? ¨ In-house
versus Outsourced conversion? ¨ Quality of
documents to be converted? Can they be scanned without some kind of cleanup activity? ¨ Indexing
schemes and execution during the conversion process? ¨ Are OCR
capabilities needed to capture information for retrieval purposes? ¨ Storage
method? With the drastically reduced costs of storage, this is no longer a big issue but
needs to be addressed. ¨ Transmission
bandwidth? In spite of the progress that has been made with cable and fiber, this still
remains a significant challenge, particularly if distribution is needed on a global basis. ¨ Standards
and/or Best Practices? Even though standard file and compression formats are available,
the technology keeps changing, always offering better performance, but possibly at the
expense of some other capability or interchange ability. In addition, the distribution of
large-format documents and CAD files may require some compromises that invoke a best
practices approach to eliminate the overloading of existing networks. CAUTION:
WHEN IMPLEMENTING A NEW TECHNOLOGY, THERE IS ALWAYS THE DECISION OF WHETHER TO SCRAP AN
EXISTING TECHNOLOGY OR SYSTEM. I SUBSCRIBE TO THE LEVERAGING PRACTICE PROMULGATED BY DR.
RAINER HOFF OF THE GATEWAY GROUP (www.gatewaygrp.com) AND OTHERS: PAY
ONLY ONCE FOR SOMETHING! THIS
MEANS THAT YOU NEED A STRATEGY THAT BUILDS ON THE EXISTING SYSTEMS (OR SOME OF THE KEY
CAPABILITIES OF EXISTING SYSTEMS). AN IMAGING SYSTEM USUALLY FITS THIS LEVERAGING
APPROACH. ANOTHER
LEVERAGING PRACTICE ADVOCATED BY DR. HOFF IS TO USE OTHER PEOPLES MONEY
WHENEVER POSSIBLE. THIS
MEANS CHOOSING VENDORS THAT ARE INDUSTRY WINNERS AND ONES THAT HAVE ALREADY INSTALLED AND
HAVE SUCCESSFUL SIMILAR IMPLEMENTATIONS. AVOID PAYING FOR CUSTOMIZED INSTALLATIONS WHERE
POSSIBLE. 2. Workflow - Sometimes
considered the backbone of the way electronic files are routed within an organization. I have always
been amazed at the amount of effort that can go into choosing something so seemingly
mundane as workflow software. Some people have accused me of not understanding the
complexities of the software problem to solve this. And in the case of defining a
transaction process, that may be true. But for most engineering and manufacturing
scenarios, workflow is usually only required for the engineering change order (ECO)
process. (I can think of some manufacturing processes where the flow of process plans or
shop floor instructions should follow the Process.) But I look at our everyday use of
email systems and their inherent capabilities, and I still wonder how big the market can
be for standalone workflow systems. My opinion is
that workflow should be purchased as part of a solution, such as the ECO process of either
an EDM or PDM system. Todays ERP systems supporting transactions for enterprise-wide
electronic commerce generally need more extensive workflow capabilities. 3.
Document Management/EDM - Electronic
Document Management systems provide storage and retrieval of 2-D documents in their native
formats, whether images, CAD files, spread sheets, etc., with the ability to group related
documents into folders. Depending on
the indexing scheme used and the application involved, this document-oriented approach can
provide 80% or more of the functionality of a PDM system at less cost to implement. The
process industry with its government-regulated documentation and the manufacturing process
in general with its ISO documentation, have been key applications for EDM systems. EDM
systems have been widely used in customer service applications and to supply documents for
the transaction-based ERP systems. The issues of
EDM systems include: ¨ Most or all of
the issues of Imaging, especially storage and bandwidth. ¨ File access
across multiple networks and document repositories? ¨ Internet
implementation? How is it accomplished? ¨ User access
privileges and security methods? ¨ Check-in/check-out
for document version control? ¨ Audit trail
for version control? ¨ If
configuration control is needed, how can it be accomplished through indexing? ¨ Degree of
coupling and interaction with CAD system? ¨ Multiple file
viewing capabilities to cover all stored native files? 4.
PDM - Product and
Process Definition Management systems are tightly integrated with CAD systems to access
and control all CAD information in its native hierarchical form, whether 2-D or 3-D. In the
customized manufacturing environment, PDM can be the ultimate provider of released shop
floor information with the degree of configuration control needed for the application. PDM
systems can also include all of the document types included in the EDM system,
traditionally at greater cost than for a document-only system. Recently, we have been
seeing progress made in PDM Internet implementations, which will have an effect on driving
down the costs of PDM implementations. The issues of
PDM include: ¨ Most or all of
the issues of EDM systems. ¨ How is
configuration control accomplished? ¨ Tight
integration is provided with what CAD systems? ¨ GUI
interface? Is it Windows compatible? 5.
ERP - Enterprise
Resource Planning systems are said to have been installed in nearly 70% of Fortune 500
companies. Unfortunately,
not all of these large dollar implementations are yielding the expected returns, partly
because of the customization needed, the training needed, and other technical and
non-technical factors. Many installations may need the added capabilities of EDM or PDM
systems to provide legacy documents and product information. ERP systems are transaction-based and tend to be
modular, allowing a company to tailor a system to address the business-critical functions
such as: Ordering -
Sales Representative takes an order and checks price including any customer discounts. If
appropriate, credit history of that customer can be checked. Availability
- The Inventory module checks stock and may notify the sales representative that one-half
of the order can be filled immediately from an overseas warehouse. It also tells the
representative that the remainder of the order can be supplied from one of their factories
within 2 weeks. Production -
The Production module schedules the production and notifies the warehouse to ship the
existing stock to the customer. An invoice is automatically printed for the quantity
shipped. Human
Resources - The Human Resources module identifies a shortage of workers needed to fill the
remainder of the order and alerts the personnel manager to the need for more workers. Purchasing -
The Materials Planning module notifies the purchasing manager to reorder components needed
to produce the product. Order
Tracking - Order tracking can be performed online by the customer, eliminating the need
for customer service to become involved, unless there's a problem. Planning -
Based on data from the forecasting and financial modules, a manager may learn that certain
products are in demand and are also highly profitable. He or she can decide to offer some
complementary products. Additional
specialized functionality can be supplied with any of the major modules. One of the key
issues surrounding ERP usage, is document redundancies between the major ERP modules. A
document strategy that employs a centralized EDM repository to provide the documents as
needed by each of the ERP modules, can reduce operating costs and provide a greater
Investment Rate of Return (IRR). ADVANTAGE:
IMPLEMENTING EDM AND ERP AS AN INTEGRATED SOLUTION PROVIDES A HIGHER IRR THAN CAN BE
REALIZED BY IMPLEMENTING EITHER ONE OR BOTH AS STANDALONE SYSTEMS. TO REALIZE THIS GREATER
RETURN, DEVELOP AN EARLY STRATEGY THAT COMBINES THE DOCUMENTS WITH THE TRANSACTIONS AND
THE CAPABILITIES OF BOTH SYSTEMS. 6.
SCM (Supply Chain Management) - Transaction-based
systems tailored to address supply chain issues. The Ordering,
Availability, Manufacturing, Purchasing and Order Tracking modules of ERP systems can be
customized to address theses issues, or specialty ERP vendors can supply streamlined
versions that address only the supply chain issues. The goal is to provide JIT deliveries
of products and components needed to assemble products to the correct release,
specifications, and performance. The issues of
implementing are basically the same as for ERP systems, but the latest trend is to use
suppliers to provide design and manufacturing input during the design process. This has
lead to a new class of technology: Collaboration and Visualization. Collaborative
design is not new, but the technology to implement it on a wide basis is now available on
the Internet. Visualization
is the latest buzzword for viewing technology, which also is not new. But the capability
to do real time viewing of a 3-D CAD model at reduced cost, without using the native CAD
software, is relatively new. Combine these
technologies on the Internet as some new vendors have done to address Collaborative design
for the Supply Chain, and you have a new tool to address efficient use of your Supply
Chain. 7.
CRM
(Customer Relationship Management) - Tracking your
customers and prospects worldwide while maintaining histories of relationships. This is an
extension of the order entry and customer service processes, and is primarily a sales tool
with an executive planning function. The ability to track customers by projects and/or
products is a desired capability that few products can do without customization. 8.
KM (Knowledge Management) - One of the
most hyped and least understood terms to come down the pike since the early days of
Artificial Intelligence. KM is a
culture that organizations need to instill to address the age-old problem of not losing
critical design or process information when Jake retires or otherwise leaves
the organization. Many companies have taken the right approach to build repositories of
knowledge assets. But many more believe that they can buy software products that can solve
the information overload. And while there may be some products that can heuristically
profile some of a users habits based on experience to filter Internet and email
information for that user, the majority of KM products are little more than relabeled EDM
or Imaging products. Creating a
knowledge environment with processes to capture the knowledge assets of your
organization is important, but it will probably be most successful once most of the
technologies of electronic commerce have been implemented. DO
NOT EXPECT TO IMPLEMENT KM AS A TOOL THAT WILL SOLVE YOUR ELECTRONIC COMMERCE NEEDS. THE
OTHER TECHNOLOGIES ENUMERATED FOR ELECTRONIC COMMERCE WILL PLAY A LARGE ROLE IN DEVELOPING
A KM CULTURE IN YOUR COMPANY. 9.
Portals - An old term
revived for a new use. Providing browser-based access to a number of electronic commerce
functions from the interface of a single system, usually an ERP system. While the
concept is good, it usually supposes that you have an ERP system as the backbone of your
organization. And while that may be the case for many companies, the ideal situation is to
have an Internet backbone with all systems accessible by browser. Many users object to
having ERP being the function that every other function has to fit into. All vendors and
systems should be viewed as part of a larger world. The world should not revolve around a
single vendors system. On the other hand, many other vendors of enterprise systems
are providing portal software packages that integrate ERP systems, another option that
should be considered. ERM and the Virtual Enterprise Every company
that sells a product (other than software that may be produced from intellectual assets),
buys raw materials, components or parts of some kind, builds or adds value, then sells the
product. The Virtual
Enterprise Model implements electronic commerce to connect the various functions and
departments of that basic process so that customers can be literally connected to the
supply chain. The back
office which maintains all of the financial transactions, and designs and manufactures the
product, is connected directly to the supply chain, while the front office which provides
all of the marketing, sales and customer services, is connected directly to the customers.
Customers can access supplier information to whatever extent the front office and back
office operations allow. Delivery schedules, as updated and agreed to by the involved
departments, should be available for online access by the customer.
If the product
is not already in production (released from engineering), the EDM or PDM system would
provide the released product information to manufacturing. Custom product
orders would automatically trigger the EDM or PDM system to release the finalized design
information to manufacturing. Collaboration
and Visualization can be utilized to involve the supply chain or to allow global design. Internet Implementations of Everything? The common
expression of every executive is to implement these technologies on the Internet. What
better way to distribute globally and to provide a known interface to users?
Unfortunately, not all of the technologies have been Internet-enabled to the extent that
they can plug and play. ERP systems, expected to be the backbone of electronic commerce,
are less Internet-enabled than any of the listed technologies. But technologies progress
and some of the smaller and nimbler ERP companies do offer Internet solutions. Also, some
of the companies that are providing portals (see above), offer a solution to a total
Internet-implementation. Some
leading-edge companies like Cisco Systems are implementing internal Internet-based, global
electronic commerce systems that include PDM and ERP functionality. By carefully choosing
the proper products, it is possible to implement most functions of electronic commerce
now, rather than waiting for a total COTS solution. AN
INCREMENTAL APPROACH TO IMPLEMENTATION ALLOWS ONE TO MAINTAIN THE STABILITY THAT IS
CRUCIAL TO EVERYDAY OPERATIONS. Business
Issues Today most
executives now understand that they need to implement electronic commerce to remain
competitive. Does that mean that it is no longer necessary to do investment analyses?
Investment analyses can provide the roadmaps to successful implementations and should not
be totally scrapped. But at the same time, extended analyses can deter the fast-track
implementations that are sometimes necessary. Obviously, a
balance is needed. One of the older methods of thinking, the time value of
money, is now being replaced with, the money value of time. Using time
wisely, acting with a sense of urgency and being first to market, can pay bigger dividends
in todays fast-paced, global economy. Timid decisions rarely propel an enterprise to
gain the top market share. Four key metrics are enumerated from the Meta Groups
(www.metagroup.com) multiclient survey, entitled ERM
Solutions and Their Value: 1. Total Cost
of Ownership (TCO). This includes hardware, software, professional services, and internal
staff costs. 2. Time to
Implement (TTI). This measures how long it takes to implement a solution, and, once a
system is live, how much longer it takes until tangible benefits are achieved. 3. Return on
Investment (ROI). While the majority of the benefits are achieved through cost
containment, respondents also quantified revenue attainment benefits. 4. Net Present
Value NPV). This calculation factors in all the TCO variables, plus post-implementation
costs and quantified benefits. REMEMBER THAT
INCREMENTAL IMPLEMENTATIONS WITH THE PROPER PRIORITIES CAN PROVIDE THE STABILITY OF DAILY OPERATIONS THAT WE ALL SEEK. A PRIORITY SCHEDULE OF THE FUNCTIONS TO BE
IMPLEMENTED WILL GO A LONG WAY IN REDUCING THE FOUR METRICS AND ACHIEVING THE GOAL OF TOTAL ELECTRONIC COMMERCE.
Richard N.
Stover is Chairman and Principal Consultant of Enterprise Resources Management (www.ermdm.com),
a strategic analysis firm. He can be reached at 480-585-5580 or email: ermdm@aol.com
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