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ERP System and Current Practices

ERP System and Current Practices. References Vernadat, Enterprise modeling and integration 王立志 , 系統化運籌與供應鏈管理 Keller, SAP R/3 process-oriented implementation Oracle ERP training handouts Shtub, Enterprise Resource Planning. Drivers for Enterprise Integration. Lower customer loyalty.

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ERP System and Current Practices

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  1. ERP System and Current Practices References • Vernadat, Enterprise modeling and integration • 王立志, 系統化運籌與供應鏈管理 • Keller, SAP R/3 process-oriented implementation • Oracle ERP training handouts • Shtub, Enterprise Resource Planning

  2. Drivers for Enterprise Integration Lower customer loyalty Lower price More choices Enterprise Shorter product life cycle Shorter time to market / customer Better quality Source: 林欽文, “Supply chain management in Taiwan’s mfg,” in 1999 CALS/eBusiness管理與技術研討會

  3. Enterprise System Integration Trend CALS SCP/SCM System integration GL Extranet EC ERP EDI CIM Supply chain integration EIS MRPⅡ MRP CAD/CAM POS Individual enterprise integration FIN SFC BOM PUR Partially integrated system ACC INV EOS Island system Time

  4. Inter-enterprise integration level Partnership control system Bank Retailers inter-enterprise interactions In-house manufacturing logistics control In-house inventory control Intra-enterprise integration level MPR Local site control systems Plant A Plant B Plant X Enterprise 1 Enterprise 2 Inter-Enterprise Integration vs. Intra-Enterprise Integration

  5. Enterprise Integration: Definition Enterprise integration is concerned with facilitating information, control, and material flows across organizational boundaries by connecting all the necessary functions and heterogeneous functional entities in order to improve communication, cooperation, and coordination within this enterprise so that the enterprise behaves as an integrated whole, therefore enhancing its overall productivity, flexibility, and capacity for management of change. The aims of enterprise integration are: • to enable communication among the various functional entities of the enterprise • to provide interoperability of IT applications, and • to facilitate coordination of functional entities for executing business processes

  6. Enterprise Integration Migration Path Business Objectives Reference Models Evaluation Criteria Enterprise TO-BE State Enterprise AS-IS State Migration Path Business Constraints Modeling Formalism Structured Approach

  7. AR Engineering AP Customer Services Order Mgmt Planning Procurement Distribution Shared Services Production The Old ERP World ERP was the Enabler of Intra-Enterprise Integration EDI EDI Supplier Network Customer Network Your Enterprise

  8. Collaborative Design Financial Institutions Financial Institutions confirmation requirements e-check e-invoice feedback confirmation e-check e-invoice CRM Fulfillment Planning Trading Exchange Customers requisition Portal delivery schedule confirmation self-service confirmation schedules 3PL Contract Manufacturing Business Process Outsourcing e-ERP Model

  9. Accounting & Financials Production Logistics Sales & Distribution Human Resources Enterprise Resource Planning e-Business Application Architecture Business Partners, Suppliers e-Supply Chain Management Customers, Resellers CRM HRMS/ORMS Employees e-Supply Chain Information Backbone Source: 鄭正中, Paragon

  10. Elements of Enterprise Information System • Advanced planning and scheduling (APS) • advanced system to provide from supply chain optimization to real-time shop floor control • Enterprise resource planning (ERP) • transactional backbone to ensure data integrity and best business processes • Manufacturing execution system (MES) • management of information related to the production processes to efficiently utilize resources (macro-level process control) • Manufacturing control system (MCS) • real-time control of the production processes (micro-level process control) • Product data management (PDM) • management of product data information across the enterprise

  11. Functions of Enterprise Information System Manufacturing Forecasting MPS MRP CRP APS ERP Demand planning and Forecasting Supply Planning Finance Supply Chain Strategic Planning Distribution Inventory Planning Project Management DRP Inventory Control Purchase Control Sales and Operations Planning Supply Chain Planning Service Management Distribution Planning Transportation Management Warehouse Management Transportation Planning Supply Chain Network Planning Shipment Scheduling Quality Assurance Shop Floor Control Shop Floor Operation Scheduling PDM Quality Management Product Tracking & Genealogy Product Structure, BOM Dispatching Production Unit Engineering Change Resource Allocation & Status Configuration Management Maintenance Management Document Control CAD / CAM Performance Analysis Process Planning MES Process Control Data Collection Acquisition Labor Management Manual Process Control Supervisory Control and Data Acquisition Programmable Logic Controller Distribution Control System MCS Human Machine Interface

  12. Shop Floor Schedule Product Demand BOM / Recipe / Formula / Drawing Resource Routing / Process Labor Characteristics Inventory Status SOP, HEALTH, WORK Instructions Resource Allocation Production Dispatching Document Control Data Collection / Acquisition Labor Management WIP Status / Traceability Product Tracking Quality Management Performance Analysis Process Management Maintenance Management Costing Product Definition Process Definition Human Resources Standard Operation Procedure Inventory Management Purchasing Distribution Production Planning Forecasting Shop Floor Operation Scheduling ERP/APS MES Order Status / Completions Resource Status / Usage Labor Status Usage Material Status / Usage Actual BOM / Recipe Actual Routing / Process Product Traceability Scrap / Waste Interactions between ERP/APS and MES

  13. Enterprise Resource Planning • Enterprise transactional backbone to ensure data integrity and best business processes • Using a single database streamlines the flow of information through a business • Four main (M) functions: • Money (financial) • Man (human resources) • Manufacturing (production and logistics) • Marketing (sales and distribution)

  14. Need for an Integrated Database Functions Objects / Outputs = Products Pn ．．． P1 P2 Pn-1 Sales / Marking Primary requirements Production Demand for outsourced parts Engineering Reference units Purchasing Order for outsourced parts ．．． Customer order Accounts payable Accounts receivable Invoices ．．． Production controlling Sales / Marketing information system Integrated database Function-oriented data islands Process : Order processing

  15. Enterprise Resource Planning Managers and stakeholders Reporting applications Financial applications Sales and delivery applications Sales force and customer service reps Customers Central Database Manufacturing applications Back-office administrators and workers Suppliers Service application Inventory and supply applications Human resource management applications Employees

  16. Features of ERP Compared to MRPII • Focus on external supply chain • Client/server architecture (3 levels) • Relationship database and SQL • Graphic user interface • Multiple database support • Front-end systems for decision support • Automated EDI • Interoperability with multiple platforms • Standard application programming interfaces

  17. Presentation Application Scalability ... ... Database Client/Server: Scalability

  18. ERP Market Size in 2000-2005 Data source: Gartner Group, 2002/10

  19. Global ERP Information Service in 2000-2005 Data source: Gartner Group, 2002/10 (in million)

  20. Global ERP Information Service Market Growth Rate in 2000-2005 Data source: Gartner Group, 2002/10

  21. Global ERP Information Service Regional Market Growth Rate in 2000-2005 Data source: Gartner Group, 2002/10

  22. Global ERP Software Market Data source: Gartner Group, 2002/10 (in million)

  23. 台灣ERP市場發展 MRP 部門 大型主機 成本 少樣大量 大眾市場 MRPII 工廠 迷你電腦 品質 多樣少量 區隔市場 ERP 企業 主從架構 速度 多樣大量 利基市場 EERP 供應鏈 網路運算 協同規劃 大量客製 1對1行銷 應用軟體 應用範圍 系統架構 管理重點 生產模式 市場特性

  24. 2000-2003年台灣ERP市場規模分析單位：新台幣十億元2000-2003年台灣ERP市場規模分析單位：新台幣十億元

  25. 2000年台灣ERP市場營收項目分析

  26. 2000年台灣1000大製造業ERP導入分析

  27. 2000年台灣中小企業ERP需求分析

  28. SD Sales& Distribution FI Financial Accounting R/3 Client/Server ABAP/4 MM Materials Mgmt. CO Controlling PP Production Planning IM Investment Mgmt. QM Quality Management PS Project System PM Plant Mainten. WF Workflow HR Human Resources IS Industry Solutions SAP R/3 System

  29. Oracle ERP System • Planning • Oracle Supply Chain Planning • Oracle Rythmn • Oracle Master Scheduling • Oracle MRP • Oracle Capacity • Procurement • Oracle Purchasing • Oracle Payables • Oracle Supplier Scheduling • Oracle Web Suppliers • Manufacturing • Oracle Engineering • Oracle Bills of Material • Oracle Work in Process • Oracle Cost Management • Oracle Quality • Finance • Oracle General Ledger • Oracle Cash Management • Oracle Assets • Oracle Financial Analyzer • Oracle Project Costing • Oracle Project Billing • Oracle Prs’l Time & Expense • Human Resources • Oracle Human Resources • Oracle Payroll • Oracle Training Admin. • Oracle Time Management • Oracle Web Employees • Process Manufacturing • Oracle GEMMS • Distribution • Oracle Order Entry • Oracle Product Configurator • Oracle Inventory • Oracle Receivables • Oracle Web Customers • Front Office • Oracle Sales & Marketing • Oracle Service • Oracle Apps. Data Warehouse • Oracle Sales Compensation • Electronic Commerce • Oracle EDI Gateway • Oracle Alert • Oracle Workflow • Oracle Interoffice

  30. Oracle ERP Solutions 固定資產管理 要徑產能 模擬 RCCP 請購作業 採購作業 收料作業 應付帳款 立帳 付款作業 銷售預測 FCST 總帳系統 主需求排程 MDS 主生產排程 MPS 物料需求 計劃 MRP 成本管理 統一發票 管理 票據管理 生產發料 生產指示 Discrete Repetitive Flow Project 客戶訂單 生產入庫 供應鍵管理 最佳化排程 生產控制 製程移轉 應收帳款 立帳 收款作業 出貨作業 細部產能 模擬 CRP

  31. Generic Functions in an Enterprise Supporting Logistics Supplier Sales & Distribution Customer EIS / DSS Procurement Acc. DB Personnel DB Orders Processing Customer Service Materials Planning Supply Planning Purchase DB Administration Production Planing & Scheduling Orders DB ATP Available to Promise Parts DB Inventory Management Finance Control HR Development Orders Delivery Operations Scheduling Master Production Schedule Production Product/Process Development WIP DB Transportation Management Manufacturing Execution Product Data Management CAD / CAE / CAx Quality Management Demand Planning Shop Floor Control Warehousing Management SPC DB BOM DB Production Engineering Distribution Management Equipment Control Warehousing DB Plant Maintenance Process Design Facility DB Source: 林欽文, “Supply chain management in Taiwan’s mfg,” in 1999 CALS/eBusiness管理與技術研討會

  32. Potential Functions in ERP Supporting Logistics Supplier Sales & Distribution Customer EIS / DSS ERP Procurement ERP Acc. DB Personnel DB Orders Processing ERP Customer Service ERP MPR ERP Supply Planning Purchase DB Administration ERP Factory Planning Orders DB ATP ERP Parts DB Inventory Management ERP FI & CO ERP HR ERP Orders Delivery ERP Operations Scheduling SCP / MPS ERP Production Product/Process Development WIP DB Transportation Management MES ERP PDM ERP CAD / CAE / CAx QM ERP Demand Planning ERP Shop Floor Control Warehousing Management SPC DB BOM DB Production Engineering Distribution Management Equipment Control Warehousing DB PM ERP Process Design Facility DB Source: 林欽文, “Supply chain management in Taiwan’s mfg,” in 1999 CALS/eBusiness管理與技術研討會

  33. Order Fulfillment Process • The process is triggered by customer’s order. • The process is aimed at fulfilling customer’s order to ensure the long-term success of the organization.

  34. Design of Order Fulfillment Process • Focus on Time, Cost, Flexibility, and Quality. • The key design factor is the way production and purchasing orders are initiated.

  35. Order Fulfillment Process Chart

  36. Part I: Outbound Logistics • Order Management • Order entry, order processing, order fulfillment • Customer Service • Customer management, sales support (post-sales service), sales returns • Sales & Marketing • Sales planning, forecast, sales & distribution system information, sales compensation, pricing & discount management.

  37. Configuration Mgmt. Object-basedArchitecture Demand Capture Order Management FlexibleWorkflow AdvancedPricing InventoryManagement Global ATP ReleaseManagement Order Management for e-Business Goal: Improve responsiveness & customer service • Demand from all sources • Customer self service • Configuration w/ guided selling • Global order promising • Advanced pricing & deals • Integrated fulfillment • Tailorable user interface • Flexible, high volume arch.

  38. Customer Service • Customer Management • Define customers, sites and contacts • Maintain customer information • Define credit limits and limits per order • Define customer agreement and payment

  39. Customer Service • Sales Support • Identify service requirement • Create sale and service employee plan • Schedule service • Sales Return • Determine return materials process • Receive and inspect returns • Credit to customers

  40. Sales and Marketing • Sale Planning • Plan sales quantity for groups of products • Evaluate planned sales quantities with data (sales revenue, rebates, discount) • Plan profitability • Forecast • Predict future price and demand • Sales and Distribution Information System • Gather, condense and evaluate data from sales

  41. Sales & Marketing • Sales Compensation • Pricing and Discount Management • Create pricing list • Define currency • Change price structure • Define discount program

  42. Part II: Production Logistics • Production Planning • Sales and operations planning, demand management, master planning (MPS), MRP, capacity planning, scheduling • Inventory Control • Inventory, WIP, logistics information system, warehouse management • Shop Floor Control • Product & Process Development • Engineering, BOM, routing, materials forecast • Quality • Planning, inspection, control, certification, notification. • Plant Maintenance • Preventive maintenance, maintenance order management, service management

  43. Part III: Inbound Logistics • Procurement • Purchasing • Supplier Scheduling • Receiving • Invoice Certification • Vender Management

  44. Part IV: Integrated Logistics • Human Resources • Organizational Management, Workforce Planning, Training & Event Management, Recruitment, Time Management, Incentive Wages, Payroll, Travel, Personal Development. • Financial Management • Investment Management, Cash Management, Depreciation Simulation, Capital Measures. • Accounting Management • General Ledger, A/P, A/R, Legal Consolidation, Asset Management.

  45. Part IV: Integrated Logistics • Cost Management • Overhead Cost Controlling, Product Cost Controlling, Profitability analysis. • IT Related Management • E-commerce (Web employee, Suppliers, Customers), EDI, Workflow, Business Intelligence System (BIS), Exception System (alert). • Project Management • Planning, Budgeting, Execution, Costing, Information System.

  46. ERP Implementation

  47. Six Phases • Definition • Operations Analysis • Solution Design • Build • Transition • Production

  48. Objective of Six Phases • Definition: Determine current and future business needs. • Analysis: Map business models to applications. • Design: Define solutions and architecture. • Build: Code and test solutions. • Transition: Train users, convert data, deploy systems. • Production: Maintain and evaluate system.

  49. 11 Processes • Business Process Architecture • Business Requirements Definition • Business Requirements Mapping • Application & Technical Architecture • Module Design & Build • Data Conversion • Documentation • Business System testing • Performance Testing • Adoption and Learning • Production Migration

  50. Application Implementation Methodology 導入方法論: AIM 導入策略 導入專案組織與計劃 Kick-Off Meeting Implementation Strategy 導入規劃 電腦化 作業管理 流程改善 Operation Analysis 作業分析 教育訓練(Training) 現行作業分析(OA) 解決方案規劃 (BRM) 應用系統設定 (Config.) 作業流程規劃 (SOP) 客製化範圍的定案 Solution Design 解決方案規劃 作業流程試作 (SOP Walkthrough) 專案小組測試(CRP) 客製化作業 Build 解決方案構築 Documentation 作業文件製作 作業文件製作 (Documentation) Transition 上線準備 相關操作人員訓練(End User Training) 操作人員操作測試(End User CRP) 上線資料準備 (Data Preparation) 正式上線(Production) 上線後支援 (Post Support) On-Production 正式上線

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