Product category:
Enterprise Resource Planning software (ERP)
News Release from: Seiki Systems | Subject: ERP at Pen Cutting Tools
Edited by the Manufacturingtalk Editorial
Team on 13 May 2008
Seiki ERP software gives process times
ERP system allows cutting tools maker to search the many jobs that have been loaded on the system, and gives the user a good idea within a couple of minutes of process time required for a job.
Sheffield, UK-based Pen Cutting Tools is supplying tooling and components for wind turbine bearing manufacturers and is keen to get the best manufacturing operations efficiency The company said it has realised this by using Seiki Systems' Enterprise Resource Planning (ERP) manufacturing software
This article was originally published on Manufacturingtalk on 2 May 2008 at 8.00am (UK)
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Managing director of Pen Cutting Tools, John Shaw, said one of the best investments made by the company was the Seiki Systems ERP.
The ERP system was purchased to replace an old manufacturing system, which the company had run for around 15 years.
He added: "We had a new IT hardware system installed with a networked server followed by the Seiki Systems software".
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Pen Cutting Tools was one of the first companies in the UK to install the Seiki Systems ERP software and a full training package was provided.
* Time saving - Shaw said that the amount of time saved in the front office by the software was incredible.
he explained: "From the data I input, the software automatically develops documentation in a logical way, from quotation to order right through to delivery note and invoice.
It avoids the duplication that was taking place with our old system, keeping the whole process as streamlined as possible".
The company runs mainly small batches, and normally the quoting process could be a restriction on the efficiency of the 25-strong company.
Shop floor staff number 22.
Now, the search facility within the software allows similar jobs to be found and essential information, such as margins, hours booked and so on, viewed before any new quotes are provided.
Shaw added: "Searching the many jobs that have been loaded on the system, within a couple of minutes I can get a good feel for the process time required for a job.
Then I only need to update the material price".
He continued: "It requires far less running around to track down the information.
The margin figure was set up for us by Seiki Systems".
"After we told them how we worked it out, they duplicated that in the system.
It helps to highlight any jobs that were taken on at too low a price and allows you to quote more accurately the next time".
* Fast turnround - although accurately costing the wide variety of tooling required to produce tightly tolerance bearings is vital to the company's profitability, a fast turnaround is also important.
The lead time from design to production of a bearing used to take four to five months, the goal now is to do it in eight to 10 weeks, including prototyping and tooling for production.
This is not easy when the material specified can have a three to five week lead time.
To avoid any material-specific delays, consignment stocks of wear parts and consumable tooling is held at the customer or by Pen Cutting Tools.
This is charged when the stock is used and has helped the company win a number of contracts - running as a Kanban system for solid carbide shoes, hot forging tools and so on.
A significant amount of raw materials is also held.
Shaw said: "I'm aware that we don't use every aspect of the ERP software but it's very flexible and the elements we do use provide more than enough benefits.
For example, I can now track our turnover as invoices are issued, on an hourly basis if I want, this is something we have never been able to do".
Shaw said that previously it would have been an end of week updated figure.
He said now it's different: "The dynamic data allows us to alter what we are doing to stay on top of the business.
It also keeps historical data so that we can track peaks and troughs to help us address issues that occur throughout the year".
* Scheduling - the company said it would be looking at Seiki Systems scheduling system soon to help manage the machine loading on the shopfloor.
And, if it is as flexible as the ERP software and able operate with how the company has to work with its customers it may well be the next investment Pen Cutting Tools makes.
Shaw said: "From our point of view it has been an excellent investment, support has been first class.
Seiki Systems makes sure we run smoothly and any issues we have with the system are addressed remotely, which saves time and is covered in our annual maintenance contract".
* About the Pen Cutting Tools products - Pen Cutting Tools produces tooling and driving units for the manufacture of bearing products up to 600mm diameter, which would typically cover most of the bearings currently used on wind farms.
The favoured design is twin spherical bearings, featuring two roller tracks designed for the relatively slow moving heavy loads.
Pen Cutting Tools has expanded its own production facilities using high-speed milling, 5-axis wire erosion and die sinking machines.
All of these processes are used to finish parts from engineering plastics, tungsten carbide, diamond and hardened steel.
Within the nacelle of a wind turbine there are sets of bearings in the drive-train that allow the transfer of the rotation of the blades via a gearbox back to the generator.
There is also a large bearing fitted at the base of each blade where it is attached to the hub.
These allow the pitch of the blade to be trimmed according to wind conditions, to maximise energy extraction and stop any torque overload during high winds.
Globally there is a shortage of the large diameter special bearings required to construct these highly efficient power generating systems.
As a supplier to the companies that manufacture these bearings, Pen Cutting Tools is constantly under pressure to deliver its products.
Established in 1963, the company said that many of the bearing suppliers are investing heavily to support renewable energy projects.
Wind and wave power generation are the most favourable at present.
There is currently a world shortage of the large bearings typically used in wind turbine equipment.
These bearings be 4m in diameter and there is currently a three-year wait for any large diameter bearings.
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