End to End Business Process Automation

Vilsons Increases On-time Delivery and Improves Business Processes.

Overview:

VILSONS GROUP from Kolhapur, Maharashtra State, is an entrepreneurial family owned business group. Commencing their business since 1948, with timber merchandise, they have now grown into full fledge diversified industrial Group manufacturing and selling building materials with net sales of more than Rs 125 crores. With the growth the company started facing similar problems like many manufacturers do -scheduling. Customers were demanding shorter lead times and Vilsons were not able to respond quickly. As a result Vilsons were losing business.

The Challenge:

Vilsons needed an ERP package that provided accurate, real-time information to keep up with the rapid sales growth.  At the same time, Vilsons was moving their equipment away from manual operation toward automation, and they required a system that could schedule efficiently. It was imperative for Vilsons to view their shop floor load at any point in time, allowing them to determine where potential problems existed and create corrective solutions on the production line before slowdowns occurred.

The Solution:

Vilsons asked Vilsoft Technologies Limited, their sister concern company to develop an ERP system which can cater to their problems. It was a challenge for Vilsoft, they had to prove their mettle in front of parent company, and they can’t go wrong. After 2 years of development, Vilsoft’s dedicated team brought Reflex-IRP an innovative ERP- a software that offered a 100% Oracle solution.

The system was perfect fit for their business. The benefits of Reflex-IRP included an extremely flexible and easy-to-use interface, multi-location, multi-plant, integration with other systems and web enabled system. Also important to Vilsons was Reflex-IRP’s high level of configurability and easy modification.

Other contributing factors included Reflex-IRP’s low total cost of ownership, planning and procurement features, and the functionality to enable a turnkey business strategy. “Our goal was to get a system that works, is easily implemented, expandable, and easily modified…and that was met,” said Anil Patel, Director, Vilsons Group. “It follows rules consistent with manufacturing, which allow us to have consistency. It is also a very logical system and flows in the way a person would imagine.”

The Result:

Vilsons believed it was important for their own growth to be involved with the technology from the beginning. That investment paid off for them.

Within the first year after implementing Reflex-IRP, Vilsons experienced a dramatic drop in overtime. Reflex-IRP gave them the ability to view their shop floor load at any given point in time and allowed them to schedule hours by department, rather than the entire shop.

Additionally, Reflex-IRP improved Vilsons reporting. They were previously facing problems in preparation of consistent reports for scheduling purposes, but Reflex-IRP provided a set of rules and procedures that support consistency in reporting throughout the system.

With the infrastructure in place to keep up with new demand, Vilsons was able to reduce costs, increase customer satisfaction, shorten cycle times, and experience faster inventory turns. They can now forecast demand to suppliers, and even send suppliers forecasts for up to a year. They have dramatically decreased lead times, and increased on-time delivery from 50 percent to 95 percent. These kinds of benefits have resulted in increased profitability and have allowed Vilsons to provide more competitive services to their customers.

Return on Investment at a Glance:

After Implementing Reflex-IRP, Vilsons, the manufacturer of roofing sheets and particle boards achieved the following return on investment.

1. Low total cost of ownership

2. Increase on time delivery from 80% to 95%.

3. Decreased lead time by

4. Bottom-line increase by 20%

5. Improved business process overall.

6. Reduced paper work by 20-30%

7. Rejection ratio decreased by 15%

What the client had to say?

“For our company, Reflex-IRP has been a perfect fit. It is a dynamic system that can expand as our company grows. We have worked heavily with the software, using it as a base to develop additional solutions for our specific needs. We have found it to be a thorough system that considers the various ways of going about business. It is also a very flexible system, allowing us to customize without compromising data,” said Rajesh Bhai Patel.

Your Business Process Automation House

VILSOFT Technologies has emerged as a leading company in providing Business Process Automation (BPA) Solutions.

The unique model of VILSOFT has largely contributed to its success:

BPA Consulting + BPA off-the -shelf solutions + Team of expert software engineerings

This model enables us to provide our client with the best & economical BPA solutions.

Our experience has largely been with non-IT companies from Manufacturing, Supply Chain & Logistics, Finance, OEM, Retail and we have consulted these companies in automation of their business processes right from including production, payroll, finance, supply chain, human resource etc..

We have handholded and supported our clients right from providing them technical expertise and skilled resources in this domain in an offshore & onsite model to implementation, training, maintenance & support. We work as a team with our clients to take care of their IT needs at cost effective rates.

Business Process Automation for Retail

Reflex-Eoffice automates a retail firm.

Our client, a retail firm*, faced a major challenge of how to integrate front line employees that have varying levels of product knowledge.

Introduction Most of the retail stores face the issue of how to integrate their front line employees that have varying levels of product knowledge, which leads to order entry errors, costly credit notes and unhappy customers, vendors and employee. Sometimes pricing varies from customers to customer and time to time or new product schemes are rolled out but employees are not aware of it resulting to unsatisfied customers. Some time customer lodges complaints but there are no histories available to see the chain of actions to resolve the query.

Similarly our client was facing the same issue. They were not able to track the customer that had walked in or the employees are not aware of the new schemes rolled out or not able to handle the customer grievances. Our client came to us for solution that would help them to have efficient customer support.

Solution Vilsoft developed a unique solution calling it as REFLEX-Eoffice. It is a product that automates all the process of an organization. Since the retail company was facing with the issue of customer tracking and customer satisfaction.

REFLEX-Eoffice had the following features that were able to tackle these issues:

• Standardize price was given
• Customer tracking was possible
• Customer history was able to tracked
• Customer grievances was able to be resolved easily
• Track the products which are moving fast

Other Features of the system:

• Predict employee performance
• Check status of the work
• Keep track of schedules
• Assigning responsibilities and duties
• Maintaining situational awareness
• Use of automated system integrates every dept

Result The keys results after the company installed Eoffice:

• Uniform pricing was able to be provided Customer grievances was able to address quicker
• Customer information were able hence easy roll new schemes
• Helped to ensure product availability at any given point of time
• Helped to track the performance of the employees

Business Process Outsourcing for Manufacturing

Reflex-IRP Reduces Manufacturing Costs by 8-10 Percent for Plastic Molding Manufacturer.

Overview KOSI Plast (www.moderngroup.co.in) is a company of Designing Plastic Injection Molded products & provides Integrated Plastic Injection Molding Solutions. They categorize them-self as service industry rather than manufacturing industry. They cater white goods, home appliance & office automation, electronic & electrical industry and automobile industry. Some of their customer’s are as follows: LG, Whirlpool, Onida, Sharp, FIAT, TATA, Godrej, Bajaj, and Philips. They have around 500-600 products and 5-6 process for each products. The plant capacity is about 12000 products a day with 3 shifts and about 150 employees. But with growth, their largely manual systems started breaking down. They had no centralized purchasing department or means of sharing information, so groups were paying different amounts for the same part from the same vendor. Delivery dates were missed because of lack of inventory control, and top management had so little visibility to the manufacturing process that they could not set pricing that was competitive.

The Challenge Kosi Plast needed a complete information system built around an ERP solution that would help manage every aspect of their manufacturing process—from purchasing and inventory to manufacturing and planning. Production department were failing to track the raw materials, production schedule, customer order and inventory. Inaccurately-engineered BOMs negatively affected the entire manufacturing process. Inventory inaccuracy due to bad BOMs led to material shortages and panic purchasing. Inefficient use of machinery caused unnecessary shop floor bottlenecks and finished goods were not coming off the production line on time, creating consistently-delinquent delivery dates.

The Solution Kosi Plast commissioned a comprehensive survey of the ERP market (both International and Local) and Reflex-IRP was selected for five major reasons: 1) a 100 percent Oracle platform-latest technology, 2) exact requirement suitable to their budget 3) excellent support, and 4) scalable open-architecture features that permitted the addition of users at any time. 5) Easily customizable upto “n” th level. The consultants that evaluated Reflex-IRP and its competitors for Kosi Plast and concluded that Reflex-IRP had all the functionality they needed. They don’t have to change the process, system will adapt according to their process. “Reflex-IRP” is easy to install, interface, customize, and maintain. It can be integrated seamlessly into any manufacturing environment and has a good scheduling flexibility and versatile options. Kosi Plast was using Tally software for almost 10 years. Reflex-IRP made them change their mindset with its smoothness in usage that forced them adapt to Reflex within 1 month of the implementation.

Kosi Plast Results

Kosi Plast started module-wise implementation of Reflex-IRP in four phases, which were completed in just four months.

Kosi Plast ResultsKosi Plast started module-wise implementation of Reflex-IRP in four phases, which were completed in just four months.

Implementing Reflex-IRP has led to dramatic improvements in every operational area. Managers now have the most current inventory and costing models available to them at all times, so they can set competitive pricing that ensures profitability. They are also able to monitor the status of work orders for components, sub-assemblies and final assemblies all online. Planning has also improved. With the previous manual planning system, it was difficult to coordinate customer requirements and design changes with production and assembly functions to meet the manufacturing schedule. Now, there is seamless coordination between all departments, while significantly reducing planning headcount. Prior to Reflex-IRP, there had been virtually no inventory management at Kosi Plast; information on non-moving or slow-moving items and stock values was unavailable. With the new tools in place, manufacturing inventory has been reduced by 20 percent.

Also, with reports such as Purchase Price, there is now visibility of the cost of every purchased item, which has resulted in better price negotiation with suppliers and a 10 percent price reduction. Reflex-IRP provides accurate data for making manufacturing decisions through reports that include online machine utilization, online work order status monitoring, online WIP components costing, online WIP sub-assembly costing, and online labor utilization.

Return on Investment at a Glance: After implementing Reflex-IRP Kosi Plast, manufacturer of Plastic Molding achieved the following returns on investment: 1. Reduced manufacturing inventory by 20 percent. 2. Improved planning and reduced planning headcount. 3. Better decision making. 4. Better Visibility 5. Better Transparency. 6. 90% efficiency achieved in plant activities. 7. Reduce error at production end by 20%

VILSOFT ERP & Product Portfolio

Our off -the- shelf, fully customizable Business Process Automation (BPA) Products & Solutions. The products & solutions are fully customizable and provide our clients seeking BPA options to save time & costs through these ready made options that can be customized to their needs.

Reflex-IRP is a Business Process Automation solution that we have developed. The solution framework is completely customizable and can be used by various industries as mentioned above.

“Reflex-IRP” offers solution that enables enterprises to compete in the prevailing market atmosphere. It handles all aspects of organization viz. Administration and Visitor Management, Marketing & Inquiry –Quotation, Order Management, Purchase, Production, Maintenance, Inventory / Stores, Sales & Dispatch, Finance, Accounting, HR & Payroll, MIS etc. IRP is highly parameterized hence most of the requirements of your organization are satisfied however it can be customized to any extent considering all the peculiarities of your business, it means system adapts to your practices and not vice versa.

Business Process Automation Solutions

We are a software & IT company providing Business Process Automation software & solution to various non-IT companies especially in Manufacturing, Retail, Logistics & Supply chain. We work with companies globally by providing them technical expertise and skilled resources in this domain in an offshore & onsite model. We work as a team with our clients to take care of their IT needs at cost effective rates.

We have experience working on all business functions for automation including production, payroll, finance, supply chain, human resource etc..

Our experience comes from building a number of value added automation solutions for our clients that have helped them in streamlining various aspects of their business processes.

We have developed Reflex IRP, which is a solution we have built in house which is being used by our clients for business process automation.

Our BPA expertise:

• Our fully customizable off the shelf software components for business processes across verticals.These components help our client to meet their automation needs quickly & within budget. We consult and handhold our clients for customization, maintenance and support in a consulting mode.
• Our strong experience & understanding of our clients’ business that allows us to provide software solutions matching the needs of their business processes.
• Our ability to provide a dedicated team for software development, maintenance & support.
• Product development, maintenance & testing support.
• Our expertise in Oracle app development & support.

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