2010 April Issue – PDM and ERP/MRP:  Why They Can’t Meet the Needs of the Shop Floor

Manufacturers who use PDM or ERP information to support their shop floor needs often see big drops in efficiency. In order to improve efficiency, they must minimize shop floor errors, scrap, rework, and walk around time. An easy-to-use system designed specifically to address these concerns can produce dramatic improvements.

PDM and ERP systems are not good shop floor solutions because the shop floor is a very different environment from both engineering (PDM) and corporate (ERP), with clearly different requirements.  It is a process-based area with predictable work flow.  Random events need to be addressed simply, quickly and efficiently to maintain production velocity.  A paperless shop floor system will provide all the information needed to do the tasks across the floor.  During production it will also collect and archive all the relevant manufacturing data.

Some key requirements of a paperless manufacturing system:

• Easy integration with other shop floor support systems
• Easy modification of custom routines without changing source code
• Simple access to information
• Ease-of-use in a work flow environment
• Easy system configuration to meet work station or production line unique needs
• Simple display of multi-media information
• Accurate revision control
• Tight procedural enforcement in order to stop errors
• Rapid response to change orders
• Electronic management of paper-driven processes

PDM and ERP systems do not meet these requirements.  This provides the basis for why they have difficulty supporting efficient shop floor operations. 

What are the benefits of a system that meets these requirements?

• Faster Returns on Investment due to greater efficiency and fewer errors
• A system that can be used by all shop floor personnel
• Support for a common enterprise model while meeting the unique needs at different plants or locations within a plant
• Minimal support costs over the life of the system
• Increased effectiveness of PDM and ERP systems with reduced costs
• Lower risk of project failure, schedule slips, and cost over-runs

Paperless manufacturing is a highly beneficial shop floor improvement project.  One company concluded that, “It’s the best bang for the buck to improve the shop floor.” 

Let us show you how your shop floor can be more efficient with a paperless manufacturing solution.  We can also show how you will get more value from your PDM and ERP/MRP systems.  Just ask.