Client Background

Client is a group company of an Indian multinational conglomerate having state-of-the-art manufacturing facilities in India. The manufacturing plant boasts of precision machinery including several CNC machine tools. The manufacturing facility is shared by three divisions (plants) of the client and needs several cutting tools based on the machining requirements. This need is handled by the Tool Crib department.

Pre-implementation Status

The user gives the Shop Requisition (which contains tool description, tool no, quantity etc.) through proper channel to the Tool Crib Department. The tool crib Dept. issues the tool if it is available in the stock. If the tool is not readily available then a PR is raised as per the laid down process to procure the tools through Purchase Department. Once the procurement is done the tools are stocked properly and given to the users as and when required. The tool crib also arranges re-sharpening of tools to reduce tooling costs.

Need Analysis

As the tool allocation and PR,PO,GRN scheduling activities were managed manually, there was no tool for monitoring these at micro level. As a result, it was difficult to provide precise status of multiple transactions for recycled / new tools at any point of time. Also, the person responsible for each activity from various departments of the company did not get to know the status and deadlines of his activities like PR,PO easily. In absence of any system for tracking the status, it was becoming a time consuming and tedious activity. Therefore, Client was looking for an alternative solution to standardize the process.

Solution

PARAM Team analysed the process, and with its proven ability, provided SmartCrib system to Client. The entire process of Shop Requisition, raising of PR, stocks etc were automated in the SmartCrib Software. Information related to all the cutting tools is made available to the user and to the management. This Fool-Proof System also restricts any unauthorised user to make any changes and will allow monitoring of the flow. In addition, SAP code generation from Logic (to achieve unique codes & easy de-coding, Pending PR & PO history. Alerts (By mail ) sent to the users of the system as per the requirement of each department are some of the key features of this software.

Salient Features of the SmartCrib Software:

• SAP data import for PR, PO & GRN (plant wise)
• Plant wise quantity with value display
• Hirarchi wise PR approval through system
• PR generation from shop (referring to available stock @ respective plant)
• Separate transaction for re-sharpening of tools
• Scrap / re-cycle decision window for returned tools
• Tracking of multiple transactions for recycled / new tools
• Issue with replacement / new tools
• Value wise transfer of tools from plant to plant
• Finding particular insert (tool) should display similar tools
• Verification - Issuance history (work centre wise)
• Visibility of available stock of all plants on screen
• Shop requisition ( issue chit for tools) through system
• Every end user should be able to see his department stock only
• Email Alert helps to notify about any new tool Request procedure, Purchase Requisition, Tool Breakage etc to inform top management

The reports generated by the SmartCrib System enabled the Top Management to quickly monitor the status of multiple projects at any given point of time.

Reports:

• Employee wise & workcentre wise tools issue, Breakage reports summary & analysis [monthly / Weekly / Yearly] (Graphical & Tabular).
• Material transfer summary from plant to plant [ monthly / yearly]
• Separate consumption report for New tools & re-cycled tools. (Graphical & Tabular)
• Material code wise consumption trend [ last 6-12 months]
• Pie chart - workcentre wise
• WIP inventory report quarterly
• Final inventory report half yearly
• Partial qty / partial purchase status tracking (popup mail status)