Non – Integrated IT Solution of Textile
Industry
Integrated ERP Solution of Textile Industry
No bridges since only one island
Objectives of the ERP Implementation
Objectives are the major high-level
characteristics that can have a great impact upon the success of any ERP
project. The objectives include characteristics such as :
Speed
Scope
Resources
Risk
Complexity
Benefits
Each of these objectives can be rated on a
scale from low to high. Interrelationships exist between the different
objectives.
Roadmap for Successful ERP Implementation
ERP to lead the pilot phase while the
organization team to lead the roll out phases with the need based assistance
from ERP consultant. Adequate training and ERP’s knowledge transfer methodology
will ensure that the organizational team is equipped to handle outs with
minimum /without support from ERP consultants. This approach will ensure that
system sustenance can be independently held by the internal organizational ERP
team. The most important step of ERP implementation is the phase called Gap
Analysis which is the step negotiation between the company requirements and the
functions a package possesses.
The first important point is clearly
defining company objectives and target making these known and recognized
throughout the entire company. Next, the manner in which the company management
is involved in the project and the speed of decisions is important. Last is the
selection of experienced consultant’s and integrators.
Project Organization Structure
In organization structure of ERP project
owner is the sponsor of project. First of all steering committee is formed. In
steering committee members from own organization members from consultant are
involved. Various programme managers are selected for smooth functioning of
the project. Project managers selected from the own organization as well as
from the consultant. Power users process owners have vital role in
implementation of the system.
Roles Responsibility of Process Owner Power
User
Quality Management
Quality Management (QM) assures that
products meet stringent regulatory standards, are safe and uniform, and meet
company product specifications. ERP QM processes are thoroughly integrated into
the manufacturing process.
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Process Owner
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Power User
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Understand and validate business process document
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Support stardization initiatives – First step in this
direction has taken by various across factory meets. Decision taken during
those meets has been incorporated in business process blueprint.
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Provide sufficient business data to consultants core
team
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Impart training to end-users
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Coordinate resolution of functional integration
issues.
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Define roles responsibility of end-users, finalize
approve authorization profiles
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Take responsibility for end to end processes
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Validate stardized reports disseminate usage to
end-user
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Ensure quick documents sign-offs
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Perform Acceptance Test – This is to be performed
during end user training
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The Quality Management (QM) process can
integrate with the following ERP modules:
Q. M.
QM Linked to invoice
verification Quality
Planning and Test Equipment Calibration
Customer complaints
Quality Inspection for incoming material
Deviation and Problem Management
Grading and Sample Management
Statistical Process Control SQC
QM Linked to Maintenance In-process Quality
Inspection
Quality Notification
Batch Management
Shelf live and Status
Finished Material Inspection
Quality Management Linked to vendor
Evaluation QMS integration and Result Recording
Certification Management
Pre Delivery Inspection
Quality inspection plays an important role
in quality management. If solid foundation were laid in quality planning
quality inspection can began. The Quality Management module covers all classic
quality management tasks, such as quality planning, quality inspection, quality
control. ERP has several QM terms that are important to note.
Quality
Planning: the creation management of master data that is required to plan
complete inspections.
Quality
Inspection: the identification of whether an inspection unit meets
specified criteria.
Quality
Certificates: documents that contain text, value, inspection results, which
are used to certify the material.
Quality
Notifications: the recording processing of internal or external problems
that result from poor quality.
Quality
Control: the combination of specification from inspection planning, results
from quality inspections, quality notifications form the basis for quality
control.
Test
Equipment Management: the management of test equipment in the form of
master data records in ERP.
The following figure shows a sample flow
that depicts typical tasks in the Quality Management process flow.
Movement of material and change of material
status ( i.e. PO receipt, or changing stocks status from Unrestricted to
Quality Inspection )
Creation of Inspection Lot
Recording of Result
Usage Decision Reject Material
Usage Decision Accept Material
Move to Block Stock
Material Approved
Unrestricted Inventory
RESULTS:
ANALYSIS # 1 ACCEPTANCE OF NEW SYSTEM ERP QM
MODULE
The data was obtained from quality control
staff about the acceptance of new system ERP QM module. The data was analyzed
tabulated as follows.
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Opinion
|
Total
|
|
Yes
|
100.00 %
|
|
No
|
0.00 %
|
The graphical presentation of data analysis
is given below.
From the above analysis it was observed that
–
1. 100.00 % respondents of quality control
department were said that they were ready to accept new system ERP QM module.
2. 0.00 % respondents of quality control
department were said that they were ready to accept new system ERP QM module.
From the observations 1 to 2, it was
interpreted that there was no resistance found among the employees of quality
control employees for implementation of new system ERP QM module.
ANALYSIS #2 EFFECTIVENESS OF IMPLEMENTATION
OF ERP QM MODULE
The data was obtained from quality control
staff about the effectiveness of implementation of ERP QM module for use in
quality control transaction.
The data was analyzed tabulated as follows.
|
Opinion
|
Total
|
|
Yes
|
100.00 %
|
|
No
|
0.00 %
|
The graphical presentation of data analysis
is given below.
From the above analysis it was observed that
–
1. 100.00 % respondents of quality control
department were said that implementation of ERP QM module is effective.
2. 0.00 % respondents of quality control
department were said that the implementation of ERP QM module is effective.
From the observations 1 to 2, it was
interpreted that implementation of ERP QM module is effective in quality
control department.
ANALYSIS # 3 BENEFITS - LEGACY SYSTEM VS ERP
QM MODULE
The data was obtained from quality control
staff about the benefits of ERP QM module over legacy system used in quality
control transaction.
The data was analyzed tabulated as follows.
|
Opinion
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Total
|
|
User Friendly System
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48.00%
|
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Easy Data Retrieval
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36.00 %
|
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Easy Reporting
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16.00 %
|
The graphical presentation of data analysis
is given below.
From the above analysis it was observed that
–
1. 48.00 % respondents of quality control
department were said that ERP QM module is user friendly system.
2. 36.00 % respondents of quality control
department were said that in ERP QM module data can be retrieved easily.
3. 16.00 % respondents of quality control
department were said that in ERP QM module reporting is easy.
From the observations 1 to 3, it was
interpreted that ERP QM module had benefits over legacy system.
DISCUSSION:
Today organizations need demonstrable
returns on their investments before they invest in enterprise software.
Customers are deming that ROI analysis be a
critical factor in their decisions to acquire new enterprise software.
The way a company organizes its ERP project
team can greatly influence the successful outcome of an ERP implementation.ERP
project teams are formed not just for implementing ERP software but also for
the ongoing maintenance required of an ERP system. The functions in the quality
management module support the essential elements of ERP system. In the area of
production, quality assurance is no longer viewed in terms of inspection the
elimination of defects alone, instead the production process itself becomes the
focus of attention. The integration of quality management in the ERP systems
provide considerable advantages because only an integrated system can support
all of the elements of a quality management system according to international
stards. The quality management module fulfills functions like quality planning,
quality inspection, quality control, quality assurance.
REFERENCE:
ERP Demystified by Alexis Leon by Tata
McGraw Hill Education Private Limited, New Delhi
E-Commerce by CSV Murthy by Himalaya
Publication
http://rhrsolutions.in/in/web/qm_module.php
http://sap-press.de/download/dateien/912/sappress_quality_mgnt.pdf
http://www.sap-erp.com/general/introduction-to-sap-qm.html
http://wiki.sdn.sap.com/wiki/display/ERPLO/ERP+QM
