For over 25 years we have been delivering business and operational solutions to the manufacturing industry. Our process for supporting our customers is, itself, one of continuous improvement, as we work alongside you designing, implementing and developing to meet your needs. Today we help manufacturing companies implement Lean.
The solutions we offer:
Value Stream Analysis
Working with your people we help you formulate the key changes needed to migrate to Lean. By mapping your production processes, including information distribution, we deliver a complete picture of your value stream. Non value-adding items are identified for waste elimination, making production much more efficient.
MRP/ERP Enhancement for Lean
One of the main restrictions companies face in moving to Lean, is an existing IT infrastructure built to support manufacture for stock. Modcomp has the technology and skills to help you adapt and enhance these IT systems to support Lean processes. This can be achieved, in many cases, with little or no change to the existing MRP/ERP software.
Modcomp’s Lean Support Modules
Modcomp’s Lean Manufacturing solution comprises three modules together with their subcomponents, each of these modules can be purchased separately but for best effect we recommend that you consider implementing the whole suite over time. The modules are:
Vendor Portal
Just in Time (JIT) production and its associated logistics management process Kanban, requires close co-operation between you and your suppliers. Our Vendor Portal provides a range of services to enable this collaborative approach:
Supply Chain Position
Vendors use the portal to register stock positions. This provides a complete view of the supply chain to improve planning and optimisation.
Demand Statistics
Our solution records stock transactions over time. Vendors can access this database to view a range of historic usage data.
Self-service Replenishment
Modcomp’s solution enables vendors to raise their own electronic replenishment orders and invoices. This function generates a bar coded Goods Advice Note (GAN) which is attached to the shipment to enable automatic reconciliation with the Purchase Order.
Manufacturing Portal
The Manufacturing Portal provides all the information necessary for production management to execute the manufacturing process in the most effective way possible. The portal provides:
Kanban
Using Personal Digital Assistants (PDAs) connected via wireless points of presence, Kanban stock usage is monitored and recorded in real-time. Integrated with your ERP/MRP system, our solution provides automatic stock position update. The Kanban module also incorporates a message system to alert vendors who will initiate replenishment.
Scheduling and Optimisation
Modcomp solutions provide the ability to view and set overall factory and individual work-cell capacity. Typically a work-cell team leader will access the system to view orders which have been loaded. Information required to build the product is available, such as component breakdown, current stock, drawings, labels etc.
Metrics
Information about what is happening throughout the supply chain is vital for Kaizen (continual improvement). Modcomp’s manufacturing solutions continually monitor and record vendor and internal process performance and exceptions. This helps vendors, managers and staff work together to improve performance.
Exception Management
In the case of an exception such as a stock out or machine breakdown, the Modcomp solution will generate exception messages to notify the vendor and/or manager responsible for rectifying the problem. Delivered using an email message, with embedded links to enable managers to drill down into the detail of the problem, there is an automatic escalation process if no response is received.
Goods Receiving
The Modcomp solution supports the automatic routing of received goods to the appropriate quality assurance or buffer stock location. Using bar code enabled PDAs and wireless technology, the goods-in receiving process is streamlined by having up-to-date and accurate information at the point where it is needed. This system works in tandem with the Goods Advice Note (GAN) generated by the Vendor Portal.
Customer Portal
The Customer Portal allows authorised customers to access a range of transaction and information services. Integrated with the back office MRP or ERP system, the Customer Portal allows your customers to check order status and shipping details; make pricing and availability to promise (ATP) enquiries and to place orders and send invoices.