The organisation of tool and mould manufacture often lags behind production technology, but not for Bierlein & Schwarz GmbH which has used WorkPLAN to integrate order and production monitoring. The company, which is based in Kalchreuth, Germany, was already using computerised planning, but found that the system in use had many limitations. Managing Director Martin Gnther explained "The scope of operation of our software solution at that time was simply too restricted, measured against current possibilities." He approached Zwicker Systems for a solution - "The answer came promptly - WorkPLAN management software from Sescoi, which provides workshop control and automated monitoring of orders."

<< With WorkPLAN every purchase order we place can be accurately allocated to a customer's order or a cost centre. >>
Martin G nther Managing Director Bierlein & Schwarz GmbH

Bierlein & Schwarz laid down three main requirements for WorkPLAN; firstly, there should be integration from receipt of the order through costing to the delivery note and the invoice. Secondly, collation of all invoicing operations; whether for orders placed, or for suppliers' invoices received; and thirdly, transparency in production, requiring a clear overview of the status and timing of current orders. Martin Gnther is sure that he made the right decision in using Sescoi. "Our productivity has increased noticeably."

To manage the introduction of WorkPLAN as quickly and successfully as possible, basic data such as production times, hourly rates and material costs must be available. At Bierlein & Schwarz a substantial quantity of information was involved, extracted from the previous software and from manual costing records. WorkPLAN has now become an important part of the organisation at the company, providing the desired integration and transparency. All the information is available not only to the foreman or group leader who carries out the costing, but to all employees who need to be involved. Martin G nther explains, "A customer sends us an enquiry which is checked on screen and then priced by our foremen, who operate as project leaders. As soon as the cost plan has been formulated, a quotation number is issued via WorkPLAN and the quotation sent to the customer. At this point the capacity implications are already known. If the quotation is subsequently modified, each employee concerned receives the new information at the same time. The project leader can then recalculate the utilisation of production capacity on this basis and reallocate the tasks. If the order is received WorkPLAN generates a unique identifier, which provides information such as new order, repair or modification status at a glance. This number permits unambiguous identification right through to delivery."

WorkPLAN contains all the relevant information, which the employees extract at the press of a button, vital for good communication in a large company. Because the order goes through to invoicing with its own unambiguous identification it is possible to look back at the total time booked against the job at each stage. This enables an assessment of the efficiency of individual workstations. In addition, by using historical information, realistic prices can be quoted for tools, and delivery times can be more accurately estimated in advance.

Bierlein & Schwarz is now ordering materials using WorkPLAN. The order is issued with the precise designation, catalogue number and order number. Martin Gnther adds, "This information must also appear on the invoice, otherwise payment will not be made. In this way every purchase order we place can be accurately allocated to a customer's order or a cost centre." He is delighted that WorkPLAN already fulfils 90 percent of his requirements. He is looking forward to the implementation of the final module when individual project leaders will be able to autonomously check for available capacity. For example, if a customer telephones for milling capacity, the project leader will soon be able to check on his computer the real-time loading of the department. The great advantage of the system is the integration and transparency - invaluable for delivery and capacity scheduling. It is this integration which permits the practical planning of orders and resources. This simply does not happen with insular solutions or non-specialised systems.

Integration in the invoicing process rapidly led to real cost savings at Bierlein & Schwarz. Martin G nther explains: "Whilst we always had wages accounts in-house, we have also brought back the financial accounting. We want to acquire all data via WorkPLAN and then transfer it to Datev."

All commercial information is now kept in-house, so the direct cost saving is also accompanied by a time-saving factor. Searching for invoices and duplicated data input has been eliminated. The decision to introduce WorkPLAN has been a complete success.