RGU_FRP Software- ADO
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Agenda
1. Welcome & Introduction2. RGU OPTI – Foundry Resource Planning System
What makes foundries so special?3. RGU OPTI – Added Value for the foundry
1. Resourceplan – Basis for foundry specific calculation, the gateway between PPC and cost accounting
2. Tool/Pattern Management – integrated foundry-specific pattern management
3. OPTI.melt – a complete optimisation of the alloy usage with coverage of all logistical aspects
4. Disposition: the basis for capacity planning and Shop Floor Data Capture
5. Shop Floor Data Capture: All possibilities in a standardised solution
6. KPI & FIS – Consistent data for a homogenous reporting7. Post Calculation / Costing
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Agenda
1. Welcome & Introduction2. Why FRP (Foundry Resource Planning) - Not just ERP?3. RGU Products
▪ RGU.OPTI▪ OPTI.MELT▪ OPTI.SAP
4. Resource plan – Basis for foundry specific calculation, the gateway between PPC and cost accounting
5. How RGU solutions works?6. Disposition: the basis for capacity planning and Shop Floor
Data Capture7. Shop Floor Data Capture: All possibilities in a standardised
solution8. KPI & FIS – Consistent data for a homogenous reporting9. Post Calculation / Costing
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• Auto Design Online
▪ Auto Design Online brings world class foundries products & technology to Indian market, with the aim to upgrade Indian foundries with world class products
▪ We are the first company in India, to introduce foundry specific software to manage Foundry & it’s Resource planning – unique product!
▪ Team of expert engineers and foundry consultant, with vast experience in foundry, to provide the best sales & support our client deserves!
▪ Effective sales and support network across India
▪ We serve
▪ Sales & Support for our partner products
▪ Engineering Services – Casting gating system design & casting simulation
▪ Foundry consultancy – Cost reduction, Foundry management
▪ CAD-CAE design & services
Auto Design Online
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• Auto Design Online – An Authorised Distributor of RGU GmbH, Germany
▪ Foundry Resource Planning Software packages
▪ RGU OPTI.Kompakt
▪ RGU OPTI.Melt
• Auto Design Online – An Authorised Distributor of C3P Engineering Software International Co., LIMITED, USA
▪ C3P develops complete Casting & Stamping simulation software packages
Auto Design Online - Partners
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Cast Designer TM
Form Advisor TM
Geo Designer TM
• Founded in 1984 by German foundry experts with profound IT-knowledge
• 45 specialized employees with sole focus on the foundry industry
• Over a 120 pan-European installations and foundry projects
The RGU
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• ERP - Enterprise Resource Planning“determines the corporate task to plan and steer resourceslike funds, assets, employees, machines, materials and ITas defined by company objectives in due time and tailored tosuit the market.“
Source: Wikipedia
• FRP - Foundry Resource Planning“determines the corporate task to plan, steer and
synchronize resources like funds, assets, employees,machines, materials, raw materials, scrap, pre-products,purchased products, external services, IT, logistics andquality assurance processes as defined by foundryobjectives in due time and tailored to suit the market.“
Source: RGU
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The term “FRP“
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Why “FRP“ – not just ERP?
ERP FRP = ERP + Resource plan + Production plan & control + QM +
Tool Administration
ProcessesWhy “FRP“ – not just ERP?
Foundry specific product structure− raw castings, treatment, cores, moulding sand− tools, mould boxes, pits− internal and external services (ESP)− casting and drawing history
Material data management− material demands− desired mixture, metallurgical
characteristic values− material test plans - variants− integrated resource and test planning
Material costing− as a material cost unit− melting book or with retrograde
accounting from the melting report− optimised calculation of the mixture
Linkage of product- & tool-data,pattern life-cycle− tool-variant part list
(pattern, core box, gravity dies..)− pattern state, changes, processes− control of downtime, life-cycles
Production planning and controlling− synchronising pattern, mould, cores, melt− pattern availability and pattern provision− tracing of castings− coordination of external services & providers
Calculation and pricing− surcharges (material, energy etc.)− price list, customer agreements− reference to item, gross & shipping weight,
charge− foundry specific planning formulas
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FRP takes care of all Foundry specific requirements
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General Manufacturing V/S Foundry market
Mechanical &ElectricalEngineeringFoundries
Most ERP software in the market are developed for g eneral manufacturing process, while RGU.OPTI developed for specific foundry segment, despite a niche market si ze!
General ERP
software
RGU.OPTI – FRP
13
What makes a casting so special?
• Geometry� size accuracy� surface
• methods� permanent/loast moulds� moulding line / hand
moulding
• raw materials� alloy, microstructure� mechanical properties
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Work flow of general Mechanical engineering
In General mechanical manufacturing process workflow is�linear, continuous process chain – General ERP solutions aresuitable
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Work flow of Foundry
In foundry processes are � non-linear, discontinuous process chains – demands for FRP solutions, not just ERP!
ProcessesProcess model (Example)
RM storage
Charge Preparation
Melting
Pattern Preparation or manufacturingMoulding
(includes stripping, curing, drying, etc)
Coating
Setting(Inserts, core, xWin)
Mould closing
Pouring
Cooling
Shake-out
Knock-off
Cleaning (Shot blasting/Fettling/Grinding)
Heat treatment
Finishing (painting, etc)
Storage/production(Inserts, core, xWin)
PackShipGoal =ship through
PPF/Ladle
1
2
Production operations in
scope:
Melting
Moulding
Core prod. & prep.
Cleaning & Finishing
1
2
Machining
Core preparation
Core Production
Core Production
SleevesFilters,
…
Rejects + Feeding gates
3
4
4
3
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ProcessesLinked continuous and discontinuous
Processes
melting,treatment
making the mixture
sand preparation
coremaking
mould
tool/pattern
management
mech. treatment
cleaningannealingexamine
...
pouring
ERP-system
orders
planning, controlling
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raw casting
Synchronized continuous and discontinuous processes
Core-shop Pouring
Moulding sands
Patterns Melting, treating
Moulding Shotblastingfettling
HT
Machined casting
machining, testing
ESP
Packaging & dispatch
A huge variety of determining factors and parameters have influence on the quality of castings
Moulds/Coressands (humidity, hardness, coating,patternsfeeders/downsprues
Meltchem. analysis, temperature, densityindexinoculation, treatment
Pouring/HT
pouring time solidification HT, microstructure
Energy-intensive processes(ratio 65-85 %)
logistics
Half-finished andfinished parts, tracingof HU, provision of HU, packaging instr.
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RGU.OPTIRGU Product
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1. RGU.OPTI – Perfect solution for small-mid scale foundries, takescare of all the foundry process right from query to dispatch.
RGU.OPTIRGU Product
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2. OPTI.Melt – Makes your melting economical through optimummelt-runs combined with cost-effective material consumption,reduced re-alloying quantities, and shorten melt times.
RGU.OPTIRGU Product
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3. OPTI.SAP – ALL IN ONE: The perfect solution for large scalefoundries who needs best of both.
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
Tool
Core packages1200
PlanningResource Plan / Scheme
(Structure of the Part groups)Machined casting ready for dispatchMachined casting ready for dispatch16901690
Machined casting(Int ./ Ext.)Machined casting(Int ./ Ext.)16001600Fettled Raw casting ready for dispatchFettled Raw casting ready for dispatch15901590
Fettled Raw castingFettled Raw casting1500150014001400
Tool/Pattern0300
CoresCores11001100Sand recipesSand recipes10101010
Core patternsCore patterns02000200
Sand
Purchased coresPurchased cores11101110
blasting
Fettling
Inspection
HT
Moulding
Core setting
Pouring
Drilling
Lathing
ESP
1090
Inspection
Raw CastingRaw Casting
PackagingInstructions
1900
Packaging
Ready fordispatch
......
......
shooting
coating
......
glueing
......
Filters / Exothermics6024Liquid metal1300
Returns / Circuit1390Pouring specifications1414
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......
25
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Expanded Resource Plan(Treeview)
Shop operations
Purchasedparts
Pre-products
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PlanningMaster Data
Description of technical identifiers• 100 identifiers on head of resource plan• 24 class identifiers• 12 alphanummeric and• 24 numeric identifiers at part master data
All descriptions are available throughout the wholesystem and are linked between modules
• Product Planning• Purchasing• Pattern Management• Quality• PPC• MM
27RGU - Cast in Software
• All needed resources for a casting are mapped into a tree structure (moulding boxes, pits, cores, purchased parts etc., even externals services and all shop operations).
• SINGLE CLICK – for parts Calculations with an unmatched detail down to the last Cent and all necessary surcharges.
• New parts are created on the fly on the basis of similar parts.• Since every layer of the resource plan is a resource plan on
its own, each layer features different technical master data (cores have different parameters from moulds, from the patterns, from the melt and so on).
• Feedback data during production can be acquired according to the detail of the resource plan, even for multitask operations of workmen.
RGU OPTI - Cast in Software
PlanningThe Resource Plan: Advantages
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RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
� Master data for process, product descriptions and all resources for the manufacture of the products
� Resource plan contains the time and quantity specifications for processes, workstations, equipment, assembly groups, pre-products and materials in the form of a task list with an integrated parts list.
� Calculation of production costs and pricing,� Capacity and workforce requirements planning� Quantities of purchasing materials required� Cost center accounting, controlling and cost object controlling
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
� Identifying the company’s KPIs and investment planning� Calculation of wages according to the remuneration model and
performance incentives.� Comprehensive material database linked with the material test plans� Integration of the tool management in which the available moulding
plates, core boxes, casting dies, mechanisms, etc. can be assigned according to the resource plan
� administration of the moulding box store, selection of suitable boxes� All specifications and cost elements are archived, so development
costs can be traced throughout the entire product lifecycle.
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
� Pre-configuration of part groups through all production stages of the cast part, including typical foundry formulae, classification characteristics for the different moulding and casting procedures,
� Administration of diagrams, documents, images, 3D data and simulation data
� User-defined formulation of surcharges and conversion to customer-dependent metal prices.
� Every change is documented, can be traced via the history function
RGU OPTI - Cast in Software
PlanningOPTI program mask: Resource plan
The gateway between PPC and cost-accounting
All shop operations (A) with default and hold times
All parts and half-finished products needed for production
Treeview
Instant cost-calculation and print-out
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Status of patterns, cores, drawings etc.
Attached test plans
PatternManagementProduct structure (RP) and BOM of Pattern
variant 2
pattern (plate) 1
core box 1
lot parts
core box 2
template, apparatus
pattern (plate) 2
. . . . . . . .
pattern instalation
variant BOM
pattern (plate) 1
core box 1
lot parts
core box 2
template, apparatus
pattern (plate) 2
. . . . . . . .
raw casting master data
structured BOM in the resource plan
core shooting ...
core box
liquid iron/-metal
feeder, filter
cleaning, testing, . . . cleaning, testing, . . .
machined casting
desired mixture
core moulding sand
mixture
moulding sand
pattern
moulding, founding
treatment
cores/core package
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Planning - PLAPlanning – Scope of work
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� Possible scope of work for Planning� Cost Center:
• The Cost Centres of the production and the adjusted cost rates• Allocate different service types with their plan-cost rates
(prop/fixed/Setting-up/Wages)
� Operations:• Allocation-List of value (Target values per time/cycle, lot, item, ...)• Sequence of work in order to control Bookings• Bottleneck for the capacity calculation• Foundry specific formulas for cast weight, moulding sand
requirements etc. are pre-defined
� Activities:• Activities can be defined to describe operations in more detail. Each
operation can posses several activities, which are carried out within this operation.
Planning - PLAPlanning – Scope of work
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� Possible scope of work for Planning� Materials:
• Material database the chemical and physical• Quality control plan & Standard• Technical Parameters
• Material group• Heat Treatment• Temperatures• Weld ability etc..
� Part Groups:• Production and offer parts• Tools/Pattern• Test Plans
� Costing Surcharges:
Planning - PLAPlanning – Scope of work
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� Possible scope of work for Planning� Article Master/ Inventory Card:
• Material• Customer• Supplier• Drawing• Pattern• Product group• Commodity group• Additional values to describe to treatment grade of the product
� Resource Plan: The resource plan describes for production parts the cost and time frames of the necessary resources:
• Operations• BOM-articles• Tools/Pattern• Supplies
Planning - PLAPlanning – Scope of work
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� Possible scope of work for Planning� Resource Plan continue..
• Purchase parts• Pre-products• Assemblies• Raw parts• Finished parts
� Costing• Standard programmed costing tool• Report costing (in standard version only)• Excel costing• Offer Costing• Order Costing• Post-Costing (by using the feedback reporting)• Semi-finished-/Finished-appraisals
Planning - PLAPlanning – Scope of work
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� Possible scope of work for Planning� Evaluation and Reports:
• Bottleneck-Information (Configuration)• SeW-Information (Configuration)• Capacities• Shift-Model - History• Shift-Model - Overview• Bottlenecks• Capacity Utilization• Techn.-log. Order Overview Prod.-Lot• PPC Orders• Voucher Reports• Development of the Calls• Order Progress• Inventory-Info• Capacity Utilization Display
Planning - PLAPlanning – Scope of work
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� Possible scope of work for Planning� Evaluation and Reports continues..
• Scrap, Scrap Rates• Tool Ready Positioning• Target Fettle-Performance (WS/Period)• Material Requirements• Voucher Reports• Serial-No.-Information• Inventories of Pre-Products• PDA-Key Figures (Diagrams)• Course of Voucher Reporting• Inventories at ESP• Melt-Information Batch, Melt-Information Date• Material Requisition• Aggregated Completion Reports• Shift Scheduling (Header)• Reservations (Bottlenecks/Calendar Week)• Sequence of Work-Inventory• Working Papers• QA-Labels
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
� Tool for the operative and strategic planning of your production� synchronies moulding, melting and casting processes� Both long and short term scheduling and capacity situations can be controlled
and monitored quickly and reliably� Check Tool availability, preparation and provisioning, and the availability of
moulding boxes and pits for mass castings� Coordinating moulding shop and core production, if necessary taking into
account pattern plate and core box allocations and combinations� Provision of liquid melt to several moulding shop areas in differing material
qualities
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
� Cycle time and planning including any cooling times needed� Continuity and capacity of cast finishing treatment, possibly with external
service providers� Forming heat treatment batches� Detailed planning in each production area - planning machine assignment to
control the production in the subsequent time-period, optimal sequences planning
� Ideal requirement for both typical series producers and jobbing producers� “Gantt diagrams” for clear scheduling and planning.
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PPC/Reporting
Shop Floor Reporting Process
Unfinished casting Finished CastingPre-product / Pattern
Preparation Coreboxes
Stock EntryStock Removal (Sand etc.)
Stock removal raw materialTransfer chem. Analysis
Melting Report
corescores
Preparation Patterns
Stock removal sand, feeders etc.Stock removal coresStock removal sand, feeders etc.
Begin MouldingBegin Moulding
stock removal meltgeneration testing order
Pouring
Pre-product
End Moulding
Finish goods report
Stock entry unfinished castingStock removal unfinished casting� fettling shop
Knock-out
Stock removal pre-finished productPackagingStock entry HU
Shipping (HU)
ApprovalApproval
Fettling shopSeparatingSeparatingfettlingfettlingshotblastingshotblastingQA reportingQA reporting
Rework
Generation of testing order
Stock entry
PackingPacking
DispatchStock entry
Machining ESP
Capture of testing data
Capture of measuring data
Machining
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PPCBottleneck Master Data
Capacities
Related shop operations
Parameters and time grades
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PPCAutomated Disposition (Scheduling)
Resource Plan with times and quantities is scheduledautomatically against production bottlenecks and alreadyscheduled production orders until delivery date is either matchedor impossible to keep� Errors and warnings have to be reviewed by resp. employee
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PPCPlanning/Load Melt-Shop
Demand for liquid melt correspondingto moulding plan
(example: 2 moulding lines)
Status pre-products (cores) andpatterns
PPCDetailed Planning / Shift Plan
continuous planning on base of scheduled production orders
generating of shift schedules(e.g. core shop, melting shop etc.)
free selection of data (filter) (i.e. machine related, material related, plate related, temperature related etc.)
production load reportper moulding plant andload of preceding and
subsequent processes
production load reportper moulding plant andload of preceding and
subsequent processes
Bedarf Flüssigeisen
0,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Stunde
t/h
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PPC/Info System
Utilisation OverviewBottlenecks
Capacity Charging Utilisationof the Bottlenecks concerning Calender Weeks
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WiP Report
Overheads
Staff Time Distribution
Tool Ready Positioning
Circulation Report
Completion Report
Stock Dispatch
Stock Entry
Scrap Report
Presence Times
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PPC/Reporting
Shop Floor Reporting
Overheads
Staff Time Distribution
Tool Ready Positioning
WiP Report
Circulation Report
Completion Report
Stock Dispatch
Stock Entry
Scrap Report
Presence Times
RGU OPTI - Cast in Software 58
OPTI – Mobile
PPC/Reporting
Application example – mobile reporting
Scan shift plan position
Order data are read via w-lan fromthe OPTI-DB and the number ofpieces confirmed on-line
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Planning - PLAProduction Planning & Control – Scope of Work
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� Possible scope of work for Planning� Bottlenecks (BN):
• To determine the available capacities per week.• They deliver are the basis prerequisites to carry out the disposition /
scheduling of the production. • Already existing operations have to be allocated to bottlenecks if
they should be considered in the disposition.� Sequences of Work (SeW):
• Summary on the basis of a chaining of similar operations (e.g. Hardening, Tempering, Releasing, etc. belong to the sequence of work: Heat treatment) which are carried out in a delimited operational area.
• SeWs serve the progress and inventory monitoring, they have impacts to the WiP-reports and the booking routines of the system.
� Shift Models:• Within the shift models the valid shifts of the company like early
shift, day shift or night shift with the working times and break times are defined.
Planning - PLAProduction Planning & Control – Scope of Work
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� Possible scope of work for Planning� Week Shift Model:
• Week shift models describe the shifts of individual company areas. They are allocated to the concerned bottleneck.
� Company Calendar:• The company calendar needs to be defined per week and shift
model. • These data are basically needed to calculate the capacities.
� Capacities:� Production Orders:
• Production orders are the basis for all activities and functionalities They can be recorded
• Manually• Automatically generated out of the customer order program in case of
make-to-order production• Automatically generated by the system in case of factory orders
• All statistical figures of the entire order including all production lots
Planning - PLAProduction Planning & Control – Scope of Work
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� Possible scope of work for Planning� Assemblies:
• The assemblies maintain all lots belonging to the production order covering all structure levels. Usually this program is only used by the system and automatically maintained.
� Resource Loads:• Resource loads are generated by the disposition/scheduling of the
production• They are generated for operations/bottlenecks and material groups
if desired.• They contain the basis information concerning
• WiP-reporting• Utilisation of the production
� Auto-Disposition / Scheduling:• The scheduling of customer orders is carried out automatically by
using the order maintenance of the sales module. • The scheduling control parameters are handed over to the
disposition process. They are defined in a corresponding list of values:
Planning - PLAProduction Planning & Control – Scope of Work
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� Possible scope of work for Planning� Auto-Disposition / Scheduling continue..
• Very early (Processing Scheduling with target delivery date)• Early (Processing Scheduling)• Normal A Customer (scheduling under consideration of capacities)• Normal B Customer (Scheduling with cumulative check of capacity
utilization)
• Cancellation of calls (possible if lots are not yet started to be produced)
• Increase of quantities (including labelling)• Generation of factory orders of stackable pre-products• Net requirements calculation• Scheduling possible on the basis of cumulated capacity utilizations• Labelling of orders (Status rules) with deliver dates deviation with
provided methods to schedule these orders manually
Planning - PLAProduction Planning & Control – Scope of Work
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� Possible scope of work for Planning� Capacity Calculation:
• Using the data of the company calendar and the concerned parameter of the bottleneck the capacities are calculated by the system.
• Necessary up gradation/editing e.g. worker is ill in week x.� Print of Working Papers:� Work in Progress (WiP)-Reporting:
• The production shop floors report the progress of their workloads. • Produced good parts• Bad parts or parts that need to be reworked by stating the reasons• The area of serial-numbers belonging to the voucher if applicable• Overhead times that do not concern the production order like
waiting times, malfunctions, maintenance, etc.• In case of inspection operations the receiver of the produced parts
and the packaging containers• The PIN-numbers of the persons doing the work and responsible for
this voucher
Planning - PLAProduction Planning & Control – Scope of Work
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� Possible scope of work for Planning� Scrap/Rejects-Reporting:� Circulation Reports:
• Monitor the progress of the production• Carry out the material bookings• Generate the Sequence of Work (SeW) balance
� Completion Reports:• The completion reports book the parts on stock and close the
vouchers and SeW balances of the concerned structure level.
� SeW Balance:• Using the SeW balances the system determines location and status
of an order within the entire production process in detail.• SeW balances can be kept for articles, orders, lots and circulation
reports.
Planning - PLAProduction Planning & Control – Scope of Work
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� Possible scope of work for Planning� Evaluation and Reports:
• Bottleneck-Information (Configuration)• SeW-Information (Configuration)• Capacities• Shift-Model - History• Shift-Model - Overview• Bottlenecks• Capacity Utilisation• PPC Orders• Voucher Reports• Development of the Calls• Order Progress• Inventory-Info• Capacity Utilisation DisplayTechn.-log. Order Overview Prod.-Lot
Planning - PLAProduction Planning & Control – Scope of Work
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� Possible scope of work for Planning� Evaluation and Reports continues….
• Scrap - Scrap Rates• Tool Ready Positioning• Target Fettle-Performance (WS/Period)• Material Requirements, Serial-No.-Information• Voucher Reports• Inventories of Pre-Products• PDA-Key Figures (Diagrams)• Course of Voucher Reporting• Inventories at ESP• Melt-Information Batch, Melt-Information Date• Material Requisition• Aggregated Completion Reports• Shift Scheduling (Header)• Reservations (Bottlenecks/Calendar Week)• Sequence of Work-Inventory• Working Papers• QA-Labels
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
� Prepare offers, processing orders, plan shipping and invoicing � Supports both trial and first sample, individual run schedule header and make
and- hold orders� Variety of logistical principles such as preview, firm order, consignment stores or
trading goods� Quick - up-to-date overview of all processes between the company - customer� Addresses and contact details, terms of delivery and payment are stored in the
customer master, with automatic currency adjustment depending on the country� Can be integrated with financing system, monitor customer credit limit
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
� Price calculation includes � Manufacturing costs, � Contribution margins � Target sales prices under consideration of raw material � Spare part surcharge policies and external services etc.
� price list functionality includes � Current material cost, e.g. daily rates aluminum and other metals. � Current excise price � Current metal and energy price agreements can be recorded individually
for each customer and material
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
� All prices are stored along with a validity date, and any changes are archived.� The preparation of offers of all of the departments Sales, Product Development
and Calculation, Tool Management/Construction and, if applicable, Purchasing.� The progress of different tasks is monitored with respect to their completion
dates, so that offer deadlines can be met.� Any changes in the course of negotiations with the customer are recorded and
follow-up dates are noted by the system for automatic reminders.
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
� Customer call-off orders communicated by EDI (Electronic Data Interchange) to make-and-hold orders are processed directly and are available without delay for production scheduling.
� Details of order confirmations, delivery notes, invoices and credit memos are also communicated to the customer by EDI.
� Any quantities or deadlines changes by customer, communicate directly to the Production Scheduling and Control. As these changes to quantities and deadlines are being recorded, the system checks their plausibility, e.g. � Have procurement transactions already been initiated? � Has production begun yet? � What are the current stock levels?
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
� When a shipping order is created, stock accounts are booked for the loading equipment and container for each shipment and customer
� Freight calculation is based on rate tables, with the distance to a delivery location and the quantities to be transported also influencing the freight costs
� Record of the commission rates for each sales representative is kept� Status of each Production order, its progress,stock levels, storage, dispatch etc.� An extremely useful management tool for quick overview of sales volume and
revenue according to customer and merchandise category, which is also linked to a profitability analysis for the item
� Report generation and online information system
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
� Integration of purchaser, supplier and store department� Master data saves usage and price units, as well as various parameters for
controlling the purchasing and technical specifications� Price list function, price conditions and delivery terms - easy to maintain� Automatic material requirements for BOM for generated scheduled orders or
can be entered manually, considering available stocks and minimum stock level requirements, batch order sizes, restocking times and the orders which have already been initiated
� The purchasing department is provided with an overview of the requirements at an early stage within the prescribed preview period so they can optimize order quantities from a cost and liquidity point of view.
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
� Evaluate the suppliers, based on delivery schedules, quality parameters as per company-specific rules defined.
� Send out delivery reminders and final demands according to various running levels, to preselect the form of communication (email, fax, print) and to save an original document with the order items
� Send enquiries to one or more suppliers to get the best price and quality goods� Incoming goods are entered in relation to the relevant orders� Incoming goods have to be checked to ensure they fulfil certain quality criteria
(visual inspection, condition of delivery and packaging correct etc.).� Provides the data for stock and proportionate production costs� Trace on real time basis flow and status of every item/material purchased
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
� Incoming supplier invoices are either entered directly upon receipt of the goods or checked against the respective incoming goods.
� Integration with finance or accounting software e.g. Tally or similar � OPTI Materials Management package is an efficient warehouse management
solution for all your products and pre-products, purchasing and stock materials including load carriers, containers, pallets etc.
� Receipt and issue postings derived from feedback messages sent from production as well as inventory and stock evaluations.
� Stock item management is a function which helps to manage articles in the warehouse using identity and batch numbers.
� Trace materials used in the current production and distribution chain
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
� Test planning for products throughout all the stages of manufacture, materials and processes.
� Test values, quality parameters and process requirements are monitored with relation to products and processes.
� Complaint Management deals with internal and external errors and complaints.� Test plans for purchasing materials, tools and equipment, also for machinery,
plant and test apparatus, even for environmental conditions and waste disposal facilities.
� Target and actual values for moulding material tests, sieve analyses or measurements of any process parameters such as temperature, moisture etc. can also be recorded.
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
� Maintain record of various quality test for each batch, test plan, sample etc.� chemical analyses,� mechanical values (tensile and bending test, notched bar impact test),� Hardness test,� Thermal treatment with the temperature� Profile and the corresponding parts,� Microstructure,� Non-destructive tests (ultrasound, magnetic particle inspection, dye
penetrant inspection),� Industrial radiography,� Dimensional tests.
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
� Limiting and target values are monitored for every process tested and the observed values recorded. These may be numerical values, attributive evaluations, or any available documents in the testing or process stage (images, logs).
� There are a number of standard techniques for transferring test values from the testing apparatus or other systems. These include the exchange of files, database tables or online link-up of the data logging program.
� If test results are recorded manually, incorrect entries can be prevented using pre-set search functions for a test job, production messages etc.
� If mandatory tests are fail - block production & prevent shipping, or it can request approval by an authorized member of staff.
RGU.OPTIRGU Product
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RGU.OPTI – Foundry Resource Planning Software
Product Planning
Production planning &
Control
Sales Purchase Quality Management
� It can also generate number of different basic messages, in particular delivery note and clearance for shipping, allow inspection certificates and test documents required
� Can generate automatic quality certificates which can be printed on multi-language forms, saved as pdf documents and can be sent by email.
� In case of any complaints, It defines which measures are to be taken, including whether it is necessary to freeze an item, a tool or parts of a batch, whereby approval for clearance is possible only by authorized staff. It can also generate reworking orders to remedy errors.
RGU.OPTIHow RGU.OPTI works? – Existing casting
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SALE � Quantity – Purchase Order� Price� Delivery date� Quality standard� Other required details….
Product Planning
� Resource plan� Check availability/plan of
required resource, material,manpower and machines
� Availability of tool/pattern, core� Generate automatic material
demand for this purchase order� Final order confirmation, if
possible to meet all customerdemand and deadline
� 500 Pump housing� Deadline – 7 days� As per given QS
� 20 ton Ingot, 10 tonreturn circuit, 10 tonscrap required
� Total 50 manpowerrequired
� 14 shifts required� Auto generation of
required bill of material� All required resource ,
material, manpoweravailable, order confirm!
Example
RGU.OPTIHow RGU.OPTI works? – Existing casting
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Detailed Production Planning
� Detailed week/shift planning� Manually or automatic allocation
of core machine, molding line,CNC machine, manpower foreach station/process
� Core production planning� Shift planning for melting, fettling� Automatic PO generation of
required resource sand, core,sleeve, ingot, scrap, filter,packaging and logistics...
� Planning for any externalservice, if any require
� Preparation for required qualitytests
� Planning and shift-manpowerallocation for heat treatment
WiP -Product control
� 500 Pump housing� 35 pumps/shift� 1050 cores on 2
machines, 5 workman in 8 shifts
� Daily required material demand for sand, filter, sleeve, core sand given to store
� DISA line 2 reserved for week 14 – 8 shifts
� Week 14 – 8 shifts 2 workman for melting, 4 for fettling, 3 CNC machine reserved
Example
RGU.OPTIHow RGU.OPTI works? – Existing casting
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� WiP – Work in progressstatus/report manually day/shiftbasis entries of produced core,mould, machined parts etc.
� RGU can integrate/communicatewith mould lime, core m/c, CNCm/c to avoid manual entries
� Chemical composition readingfrom spectrometer
� Man machine capacity utilization� Rejection, machine breakdown,
overtime report/details� Real time basis tracking of on
going work mould line, m/c shop,quality or dispatch
� Quality test, heat treatmentstatus report
� Quality test certification
WiP -Product control
� 36 mould/shift in yesterday night shift
� Spectrometer test specimen has 0.8% carbon less then required, add 20KG Iron
� DISA line was on hold 2 hrs for maintenance
� Feedback-additional shift because downtime of DISA line
� CNC m/c is under utilization or over loaded
� One batch failed required hardness,
Example
Logistic
RGU.OPTIHow RGU.OPTI works? – Existing casting
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Example
Quality Management
� Hardness test results, X-Rayresults and shrinkage leveldetails
� Quality certificate print/report
� In X-Ray method level 2 shrinkage observed
� Correction steps, if not acceptable
� Dispatched quantity record� Truck, transporter details
Logistics � 500 parts dispatch as per schedule
Sales � Invoice generation� Part acceptance certificate from
client
� Client approves the casting received
RGU.OPTIHow RGU.OPTI works? – Existing casting
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� Required Packaging planning onorder confirmation
� Resource plan e.g. trollies,pallets, truck scheduling etc.
� Track of delivered goods� Shipping notes� Received goods notes
Logistic � 250 pumps dispatched in 2 days
� Received parts on client side
� 2 truck booked for week 14, Truck number, driving license record
Example
Sales � Received goods notes� Shipping notes� Invoice generation� Client quality test confirmation –
parts acceptance certificate� Coordination with finance for
payment
� Client received 500 pump parts
� Client approved and acceptance certificate
� Invoice and payment follow-up
Complaints/feedback
� Complaint/feedback from clientsif any
RGU.OPTIHow RGU.OPTI works? – New casting
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SALE � New product inquiry� Price� Delivery date� Quality standard� Other required details….
Product Planning
� Resource plan for samplecasting
� BOM Material for pattern/mould� Schedule
� 1 week for 2D-3D &simulation
� 1 week for pattern/mould� 1 week for trial, quality test,
dispatch� 1 week buffer time
� Cost for sample casting
� New pump housing casting required
� GGG 40� Sample casting in 4
weeks
� Drafting-simulationengineer require forweek 14
� 2 CNC m/c required forpattern
� 3 pattern expert requirefor week 15
� Special raw materialrequired for melting toachieve require gradefor sample casting
Example
SALE � Order confirm for Sample casting
RGU.OPTIHow RGU.OPTI works? – New casting
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Detailed Production Planning
� Detailed week/shift planning� Manually or automatic allocation
of core machine, molding line,CNC machine, manpower foreach station/process
� Mould/Core production planning� BOM for pattern/mould� Planning for melting, fettling� Automatic PO generation of
required resource sand, core,sleeve, ingot, scrap, filter,packaging and logistics...
� Planning for any externalservice, if any require
� Preparation for required qualitytests
� Planning and shift-manpowerallocation for heat treatmentWiP – Sample
casting
� 3 CNC machine occupied for week 15
� 2 Pattern maker occupied for week 15
� PO generated as per BOM for Mould, core, scrap, other material
Example
RGU.OPTIHow RGU.OPTI works? – New casting
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� WiP – Track actual status ofwork in progress sample casting
� Chemical composition readingfrom spectrometer
� Quality test, heat treatmentstatus report
� Quality test certification forproduct approval
� Rework on mould/pattern, if anyrequire
� Save the possible tried variousgating system design model,drawing , pattern details, results
WiP –Sample casting
� During machining, some shrinkage has been found, rework on gating system design
� After pattern modification, another trial requires
� Hardness value of sample casting is below customer requirement
Example
Quality Management
� Hardness test results, X-Rayresults and shrinkage leveldetails
� In X-Ray method level 2 shrinkage observed
� Correction steps, if not acceptable
RGU.OPTIHow RGU.OPTI works? – New casting
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� Sample casting dispatch� Various reports, Sample casting
cut sections, quality test dispatch
Logistics � Sample casting dispatch on time
Example
Sales � Sample casting approval andacceptance certificate
� Pattern/mould approval� Invoice generation
� Client approves the sample casting for mass production
If client confirms the order for mass production, f urther steps will be followed in RGU as explained earlier for “Existin g Parts”
MES / ERPIntegrated Order Processing
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• The best part about RGU is, it can be integrated wi th other existing ERP/Accounting software, if require. However independent RGU is still a preferable choic e for most small and mid scale foundries.
• Our expert engineers are well verse with technology and skill to integrate the software for two way flo w of communication.
• Integration with standard finance, accounting software e.g. Tally, BAAN etc.
• RGU team is capable to deal with any level of detai led customization, if foundry requires. That too at any level right from query to dispatch.
MES / ERPIntegrated Order Processing
Disposition Process ControllingSales/ Purchase
Prices, Quantities, Dates
Customer OrdersCustomer OrdersFrame OrdersFrame OrdersCalls / EDICalls / EDI
OC
Generation P-Order Resource plan / Item MasterWorking Program, Bill of Material,Pattern/Tools, Resources
Bill of pattern/ToolWorking Program
Bill of pattern/ToolWorking Program
Date–Confirmation
Targets
Quality Management
Test Certificates
Quality ManagementPlanning of Tests,Test- and Process ValuesTest Certificates
Orders on Hand
Orders on Hand
Needs ( Feeder, ESP ...)Prices, Quantities, Dates
Auto – Mat. Needs
Shipping NotesShipping NotesInvoicesInvoicesCredit NotesCredit Notes
Certificates
Evaluation of the actual timesPost-Costing
Detailed Planning
Combination
Detailed Planning(Week/Shift)Machine Utilisation, Order, BatchesCombination
DispositionDisposition of Production LotsScheduling, DispatchingConfirmation Delivery-DateLists, Work papers
Material ManagementMaterial ManagementESP
Mould Facilities...
WiP-ReportingAuto(BDE / MDE)Core Shoot.-M.Mould Facilities...
Interfaces
WiP-ReportingManuallyPrint PapersPieces, Times...
Incoming GoodsIncoming Goods
Stock exits (retrograd)Stock entriesStock exits (retrograd)Stock entries
DemandsPurchase OrdersPurchase Orders
Finance
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Evaluations/Info SystemFIS - Bottleneck survey
Integrated Foundry Info System (FIS) - Web access to mission-critical information and management cockpits
Evaluations/Info SystemKPI: Daily Report
MOULD004/00 Daily Report 2012-11-09 / 17:02
Selektion : 2012-01-05
(for Management Opratives)
Production data Unit Day Month Year
05.01 01.2012 2012
Production good parts tons 1947 14652 14652
Dispatched castings tons 1867 13856 13856
Rejects w/o return % 4,5 4,24 4,24
Rejects w/ return % 4,5 4,67 4,67
Downtime moulding lines % 26.0 14,58 14,58
FTE / good parts h/ton 3,50 3,46 3,46
Yield % % 70 67 67
Good parts / Moulding line operation time tons/h 20,79 21,34 21,34
No. of moulds on moulding line pieces 12563 51227 51227
No. of moulds on moulding line Cycle/h pieces 260 245 235
No. of moulds on moulding line A Cycle/h pieces 112 85 85
No. of moulds on moulding line B Cycle/h pieces 240 212 212
No. of moulds on moulding line C Cycle/h pieces 240 234 234
No. of moulds on moulding line D Cycle/h pieces 153 159 159
electric power / melt KWH/ton 732 728 728
gas / melt KWH/ton 0 0 0
Employee FTE 240 240 240
Employee temporary staff / ESP FTE 12 12 12
Employee on vacation FTE 15 0 0
Employee ill % 4,0 4,0 4,0
Vacation % 6,3 6,3 6,3
Absence % 3 2 2
Stock level finished parts tons 28598
Stock level half-finished parts tons 13567
Stock level total tons 42165
Stock level finished parts consignment stock tons 0 0 0
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Evaluations/Info System
FIS - Online InfoInquiries Overview
112
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Evaluations/Info System
FIS - Online InfoInquiry Tracking
114
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Evaluations/Info System
FIS - Online InfoCompany Calendar
115
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Evaluations/Info System
FIS - Online InfoProduction Schedule (Cores)
116
PlanningPost Calculation / Costing
Output via Excel Output via Printer
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OPTI.meltMaterial & Melt Management
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� Delivers extensive melt process planning for all melt and treatment stepsat charge, ladle and casting levels.
� Delivers accurate charge composition and post charge compositions byoptimizing the usage of materials, especially expensive metals andferroalloys.
� Enables preliminary costing to be carried out, calculating the requirements for scrap, alloying materials and metals
� Provides online support for the smelter, reduces melt times significantly and thus increases melt capacity
� Reduces energy consumption per ton and supports energy management at the point of highest consumption, which in turn leads to considerable cost savings
� Starting with the calculation of an optimal charge composition, all the steps of the melting process are recorded, documented and then made available for detailed evaluation
OPTI.melt
Material designations
Designation 2(Norm 2, customer)
Designation 1 (Norm / Standard)
Ident-No. sort of meltIdent-No. circuitCost schedule mateirial/circuitStandard-test plan Material groupWelding specCutting data processing
Material
Test values and properties
Target values for material
Test groups,Test conditions, Test values
Test plan– Norm 2
Test plan – Norm 1
Annealing specificationAnnealing specification
Structure examiniation
Charpy, hardness
Tension / bending test
Chem. analysis
Norms, specifications,...(describing objects as graphic, Word, Excel, ...)
Price agreement / validity
Price list(Daily prices)
Price basis, customer
Target composition, multistep if applicable, base iron, treatment
circuit
Pig iron
Scrap
Ferrous alloys,...
Energy
Coke
Melting
Structure of the material data
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OPTI.meltResource Plan of liquid melt
The liquid melt is a pre-product, so it hasist own part-ID
Specification on raw materials, Scrap, curcuit, energy and melt-shop operations
122
OPTI.meltAlloy Definition incl. Target Analysis
Target analysis with defaults for batchpre- and post-calculation
Formulas für batchcomposition
Linkedpricelists
Material-Id.Nr. circuit, swarf
Identifier and testplanper variant
ID-Nr. Ofmaster dataliquid melt
Alloyparameters
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OPTI.meltPlanned costs for molten melt
Planned production costs per ton – basis planned internaltransfer price
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Calculation of the charge composition
Optimisation model for the most cost effective use of materials
(non-linear, simplex)
• With / without considering the raw material stocks
• Relation charge / furnace or standard composition
Options
OPTI.melt
•circuit types, chips•Materials group•Formula
Alloy/melt
Restrictions e.g..Proportion of scrap, totals
Target & limiting valuesChemical analysis
Usable raw material groups
Melt specifications
•Price depreciation factor•Classification scrap/circuit•Type of inventory mgmt.
Raw materials
Stock total/Per storage location,Pieces
Actual analysis
Allocation of raw material groups
•Compulsory specification•Desoxidation •Suitable material•limitations
Alloy specificationFor material usage
Alloy – Raw Materials – charge composition
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OPTI.meltMelt report with charge- and rebatching calculation
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RGU-SAPRGU OPTI.SAP - All In One
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Integrated quantity and value flows
Foundries’ specific requirements
Integration solution
The integration platforms are SAP-PI and RGU-OI (OPTI Interface), in which the data is exchanged via HTTP protocol in XML format.
RGU-SAPRGU OPTI.SAP - All In One
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SalesSD
Materials ManagementMM
ControllingCO
Financial AccountingFI
Product planning,Resources plan
Materials master/ Parts master
Master Data
Net requirements calc.
Sales Order
Purchasing/procurement
Scheduling
Detailed planning
Needs,
deliverylots
Planned
orders
Quantities
–deliveryconfirm
ationP
rod.-orders
Needs
Purchased
articles
Tools management
Quality management
PDA / MDEControl station function
RückmeldungenFeedback
Dispatch/invoicing
Production order/ Cost collector
Stock levels
Feedback
quantities/times
(arrivalfinal product
RGU-SAPRGU OPTI.SAP - All In One
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RGU-SAP datacommunication, avoids multiple entries and efforts
RGU.OPTI � SAP SAP � RGU.OPTI
� Master data such as accountsreceivable, creditors, costrates/tariffs, personnel
� Material masters of sales goods (orOPTI managed) purchased material
� Customer orders/delivery plans,requirements
� Goods receipt by third party agent� Delivery note and stock levels
� Resources planning (work schedule, parts list) and parts masters of preliminary products
� Scheduled production lots as production orders
� Service notification, inward and outward stock movements including retrograde bookings
� Dispatch notification or dispatch preparation to third party agent)
� Working papers, production planning, tools management QS/QM
� Inspection certificates
Contact usThank You for Your Attention!
Auto Design Online: Authorized Distributor of RGU GmbH
Website: www.auto-design-online.com
Email: [email protected]
Contact Person: Mr. Bhushan Bhatt
Mobile: +91-9824247774