1 Introduction
Economic globalization and the arrival of an era of diversified markets require that enterprises must establish an efficient and dynamic rapid response system. Informatization is an inevitable choice for enterprises and a weapon and means to enhance the competitiveness of enterprises. However, the introduction of ERP system in the enterprise process, the implementation is an extremely crucial and most easily overlooked link. Because the success or failure of the implementation of the final decision of the full effect of ERP. According to incomplete statistics, there are three situations in all ERP system applications: only 10% -20% of system integration realized on schedule and on budget; only 30% -40% of system integration or partial integration is not achieved; ; Failed but accounted for 50%. Therefore, fully grasp the essentials and difficulties of ERP implementation, the use of scientific methods of implementation.
2, pump industry characteristics analysis
Pump is the mechanical energy into liquid energy, used to boost the liquid transport machinery. Pump is the most widely used in the national economy, the most common general machinery, in addition to water conservancy, electricity used in large numbers, especially in the most petrochemical production. From the division of industry point of view, the pump industry is a typical mechanical equipment manufacturing industry; from the basic types of manufacturing systems, a typical discrete manufacturing industry, the production process has a "processing - assembly" of the nature.
1) The characteristics of the pump industry products
Pump product structure is complex, and the process industry is different, its products are not fixed, product composition changes with the market changes. Due to the complicated product structure and heavy design task, not only the continuous development of new products, but also a large number of variant design tasks in the process of producing old products, the enterprises require strong product development capabilities, including pump performance, wear mechanism, resistance Grinding materials and other aspects of research capabilities.
Although the production of each product needs to go through the blank manufacturing, machining, procurement of purchased parts, parts assembly and machine assembly process, but different manufacturing processes are still very different.
In addition, the pump industry products also have a more distinctive features, under the pump structure changes in parts material is very frequent, basically each customer has its own designated parts of the personalized material requirements, resulting in a large pump products Some are one-time.
2) pump industry management features
Pump industry customers are more concentrated in the water conservancy, chemical, metallurgy, electric power, mining, coal, building materials and other industries, based on the particularity of these industries, orders and commodity parts combination of the ordering model is more common, usually for large projects Overall solutions, project-based personalized needs more and more urgent.
In terms of sales, sales management is mainly conducted in the form of a combination of sales in the form of sales areas, industry-specific solutions and the like, and sales of standard products.
3) pump industry production management features
Pump industry has a common mechanical industry, but also has the pump industry personality. Production methods include mass production of standard products, but also individual and small batch production. In the manufacturing mode, not only need to support multiple varieties, different batch production types, but also need to support the single-piece production type, inventory stock-type production and project-based personalized production model.
Long product life cycle, short production cycle up to 1-2 weeks, long production cycle of more than six months. Production planning is difficult to control, resulting in frequent changes in the production process; Plus more personalized requirements, the production process of personalized management requirements, the production process is difficult to control.
4) pump industry cost accounting features
Due to the long pump product sales cycle, some large pump products through the project even back up for more than a year, the sales profit is difficult to analyze. Coupled with the product structure and the high degree of personalization of the production process, especially for the project-type large pump products, cost accounting is particularly complicated, difficult to refine the management, usually only after the accounting.
3, the common point and difficult analysis
ERP system in the implementation process has some common links that need special attention, it is implemented in different industries have the same importance.
1) Preparation of basic data
"One-third of technology, seven management, twelve minutes of data", the popular phrase in the ERP industry fully illustrates the importance of data in the ERP implementation process, and the preparation of basic data is even more important because Pre-basic data preparation is to ensure the correct operation of the system key. The basic data in ERP include material code, bill of materials (BOM), organizational structure, warehouse property settings, etc. Before basic data preparation, it is essential to fully instill basic data preparation in the relevant business units and information center implementation team importance. In addition, the data preparation process, it is necessary to highlight the work efficiency and data accuracy of both. Each basic data preparation to be determined in advance to complete the time, and the implementation of the time and accuracy of the corresponding assessment.
2) project implementation supervision and feedback mechanism
Implementation of the implementation of both parties to implement the plan to implement the next push, if the following departments are not in accordance with the requirements or do not fully follow the requirements of the implementation will have a resistance to the successful implementation of ERP, the establishment of project feedback and oversight mechanism is to play this role. Weekly planning will be useful in conjunction with the wrap-up meeting to seek out departmental support for arranging weekly tasks and reflecting the problems encountered during implementation. In addition, the implementation plan implementation process, as far as possible to take "first and secondly loose" strategy, especially for those who do not enforce the enterprise; and this point in the beginning of the project should be controlled, or behind the control or management can not be Strength.
3) Business process reorganization and software functions adaptive settings
The actual needs of software vendors and customers will always have some discrepancies. ERP system to standardized and standardized business processes as a precondition, so if you want to successfully apply the ERP system, you must re-design and optimization of business processes. However, the reorganization of any business process is for enterprises to pay the price, therefore, requires the software product features set to adjust the process of restructuring and enterprise integration, select the best combination of points, to meet the requirements of both sides of the premise Under, so that the cost of the business to a minimum. Of course, taking into account the necessary restructuring of the company's future development needs to be resolutely pushed forward.
4) Training
The importance of training in ERP implementation is well-known and, at different stages of implementation, training is required for different content within different people's organizations. However, the implementation experience of the ERP project shows that the implementation consultant of the software enterprise firstly carries out the team training of the client enterprise and then they train the end-user of the enterprise again. This two-level training not only can reduce the work of the consultant Volume, but also help customers for the system of post-maintenance. In addition, the training after the assessment and reward and punishment is also a very crucial part, to be implemented.
4, personalized points and difficulties analysis
Pump products, processes and orders of the characteristics of the decision of the pump ERP implementation process has its own special points and difficulties need to be personalized part.
1) material classification, coding and configuration
The complexity of pump product structure to pump enterprise ERP implementation of material classification increased a certain degree of difficulty. Can be classified according to the product line, subdivided into finished products, spare parts, roughing under each series, subdivided by common parts and non-common parts under the parts; also can be directly divided into finished products, semi-finished products, Categories, and then in all major categories and then specific sub-categories and subcategories. In short the material classification according to the actual situation of enterprise materials, but also take into account the system in the future authorization of the material category, the financial account settings and other factors, and let classification determined earlier, or behind the coding work can not be carried out.
As the pump business is mainly produced according to the order, so many products and the corresponding coding is one-time, and as the customer needs changes, many purchased parts of the coding needs to continue to add in the follow-up, companies need to arrange staff of relevant departments Familiar with coding and maintenance work as soon as possible.
In addition, for some frequently-changing material-related information to consider not placed in the coding, and placed in the configuration information, such as adjusting the pumping pipe, adjusting the length of the protection tube, motor and bearing manufacturers, paint color and so on.
For the finished product parts and components of the material combination information, as the case may be. Some pump companies often change the quality of finished products parts often have six or seven kinds, and each part of the material changes in three or four kinds of circumstances, through the combination of a pump which may appear inside the parts material combination information Of course, there are many combinations that do not happen at all. If the material combination information into the code, it will generate a large number of forever useless coding, and need to spend energy to BOM them; if the material combination information into the configuration, the number of material coding will be greatly reduced, in advance Do not need to enter a lot of useless BOM data, but some work to maintain the latter part of the BOM.
2) Customer BOM
The most prominent feature of the pump industry is the individualization and diversification of customer orders, which requires that the ERP system can generate corresponding sales orders according to customer requirements in the sales management subsystem and configure the corresponding material composition structure (customer BOM ) Assurance plan decomposition and the subsequent quota picking corresponding BOM data. Moreover, the individual needs of customers, some pump components under the structure of the product is mandatory, and some are more than one election, some optional, so the software features set to meet the customer's personality Demand.
3) Order changes and plans, work order adjustments
According to statistics, some pump business sales orders change the total orders as high as 80%. The types of order changes include: ① change the delivery method, delivery location and other external parameters; ② increase the number of products in the sales order or add new products; ③ reduce the number of products in the sales order, and even cancel the sales order; ④ sales orders The unit price or delivery time of the product is changed.
The first situation is better handled, if the order has been audited or decomposed, issued a work order, do a direct change notice to the relevant departments can be; the second case requires additional sales orders, and new documents To be associated with the original order (for example, by the same contract number), then MPS is generated for the new order, and is decomposed and the work order is issued. The third situation also needs to add the new document and the original order, only the quantity in the order , The amount should be offset with the original order, and notify the relevant departments with the change notice to adjust the work order execution plan; the fourth case when the unit price changes, but also need to add a new document to associate, if only to change the delivery date, Relevant personnel need human control in the actual production scheduling.
4) Support four kinds of production methods
Due to the complexity of the product structure and processing and the diversity of customer needs, it is decided that the ERP system must be based on production and manufacturing: order design, order production, order assembly and inventory production Type and delivery mode.
In order to track the above four production modes, the project hierarchy can be divided into MPS, products, semi-finished products and raw materials. If there is an order, in order to achieve the above four types of production, it is necessary to control whether different levels of entities bring in the corresponding order numbers .
5) The combination of MRP and JIT
Standard parts, purchased parts and self-made pieces of a complete (specifications, materials, quantity, delivery time and quality, etc.) directly affect the product assembly progress and delivery time, due to more emergencies (such as customer rush orders, , Changes and other circumstances), once the progress of the assembly for some reason failed to implement the plan, it will lead to on-site waiting and individual parts backlog occupy the assembly area and so on. If you can not effectively prevent and adjust the plan in time, it will cause a vicious cycle. The traditional ERP system is difficult to prevent this phenomenon. According to the idea of JIT, MRP plans and procurement, outsourcing and self-made plans are pulled out according to the actual progress of the assembly. The time, place, varieties and quantities of ingredients are pre-assembled according to the actual needs of the assembly, delivered on time and implemented "matching management" Improve the product assembly of supporting.
6) Fine workshop management
The refined management of the workshop is mainly to strengthen the implementation of the workshop, report the function and record the abnormal occurrence and treatment of the workshop. ERP system should be able to timely feedback workshop production picking and feeding back material situation, the production flow records, production records, finished product storage records and other related information; timely reporting work center processes, dispatch orders to complete the situation; timely record The capacity of the work center prior to each scheduling and the anomalies and handling measures in the production so that the production department can get a detailed understanding of the status of the entire workshop and the production process and the overall control over the implementation and assurance of the production plan Delivery on time.
7) Fine costing
At present, many pump companies cost accounting of the original obsolete data, including the planned price data obsolescence, working hours quotas inaccurate. The planned price accounting method can not keep up with the changes in the market and can not monitor real-time costs.
Therefore, the implementation of the ERP system, in the refined cost management requirements of the system can be used according to the order, by product accounting, by shop accounting (or even by process accounting) and other accounting methods, and accounting orders or product at the same time the actual cost. This requires a reasonable definition of payroll, manufacturing cost allocation rules in the process of collecting data related to cost accounting, and the system automatically tracks and recalls the product warehousing, spare parts picking (withdrawal, feeding) records corresponding to the orders ; For some materials is not easy to determine the actual cost of the material, according to the standard cost of processing, such as the production of a special shape of the parts need to take the plate, then the amount can be used according to the standard amount to handle.
8) multi-unit materials
Pump parts involved in the multi-unit mainly include steel, tube blank, rubber, etc., but there are differences in the use of multi-unit, such as steel, rubber strip between the main unit and sub-units have a stable conversion relationship , You can set the sub-coefficient in advance to be controlled, and the blank tube blank material unit and sub-unit conversion coefficient is changed, a tube material can be divided into several blank for machining to form a semi-finished product is uncertain, it can only be manually entered The main number and the number of times.
In addition, steel and round bar, channel, flat steel, steel, steel and other types of calculation of the conversion factor when there are different formulas, and the proportion of ordinary materials and stainless steel is also different, these are to be noticed.
5, concluding remarks
ERP implementation success or failure for any one of the business development are crucial, especially for the development of a good pump industry is even more so, if the business invested a lot of manpower, material and financial resources in exchange for the implementation of a failed outcome , Then companies not only lost money, but also lost a good opportunity for development, may therefore be sluggish. Therefore, the implementation of the ERP pump industry to fully grasp the implementation of the key points and difficulties, try to avoid detours, thereby enhancing the success rate of implementation.
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