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ERP for the Rubber & Plastic Manufacturing Industry

ERP Software for Rubber & Plastic Manufacturers

Rubber and plastics manufacturers produce a wide variety of products increasingly sourced in smaller quantities from a wider base of customers.Global competition has also increased the pressure to find new methods for profitability. And, ever present is the volatility threat of raw material prices. The main challenge for these manufacturers lies in handling the immense variety of products, and the complexity of producing quality items within existing capacity. Industry reports show that leaders typically have an 85-percent capacity utilization with laggards closer to a 50-percent capacity utilization.

(Includes: injection molders, extruders, film and bag processors, blow molders, thermo formers, and compounders)

What Makes the Rubber & Plastic Market Unique?

Immense Variability

Immense Variability

Customers demand variety with their product choices, which the Rubber & Plastic market provides. WorkWise ERP software aims to make sure that both businesses and customers have those options.

Growing Competition

Growing Competition

Compete with and stand out from others in this growing industry with the help of WorkWise ERP software, which assists with retaining and forming long-term customers.

Increasing Customer Demands

Increasing Customer Demands

WorkWise ERP features include inventory and performance management helps with dealing with the increase of customer demands.

High Degree of Flexibility

High Degree of Flexibility

The Rubber & Plastic industry requires extreme flexibility around the clock. WorkWise ERP meets those demands, helping to seamlessly run business operations.

With customers demanding more variety, shorter lead times, and lower prices, this industry requires great flexibility while still maintaining precision execution. A manufacturer must always stay vigilant to apply lean practices, and apply tailored solutions to eliminate all waste. Customers also are demanding a closer relationship with easier sharing of information on products, orders, changes and design.

Fortunately, WorkWise ERP software has unique features that address these problems, helping to bring these challenges under control.

WorkWise ERP Software for Rubber & Plastic Manufacturers

+- Challenges Faced by Rubber & Plastic Manufacturers


Competition

  • Low cost global competition
  • Need to retain and grow long term customers
  • Availability of domestic competitive capacity
  • Increasing price competition

Customer Satisfaction

  • Poor delivery performance
  • Long delivery promise dates
  • Lack of formal connection to customer
  • Unpredictability of material availability
  • Sparse communications with customers
  • Shorter product lifecycles
  • Understanding customer demand

Costs

  • Thin margins, can’t invest in equipment that is more productive
  • Continued downward product prices
  • Volatile raw material costs
  • Control of waste
  • Need to reduce overcapacity and cost
  • Accuracy of job costs must be improved
  • Improve cycle times
  • Lower setup times
  • Need to reduce operational costs
  • Need to reduce administrative costs
  • Low capacity utilization (below 85%)

Complexity

  • Decreasing high-volume-low mix orders
  • Wide variety of input materials, blends
  • Variability in methods and tolerances of expansive materials
  • Production schedules that must match those of the customer needs
  • Difficulty in demand planning and forecasting
  • Insight into operational performance
  • Short response times to changing product mix, demand and customer specifications
  • Need to collaborate with customers on product development life cycles
  • High level of documentation that must be managed and tracked

Productivity

  • Need to optimize capacity
  • Improve cycle times
  • Need to streamline processes, lean principles
  • Need to raise productivity
  • Need to better utilize all resources
  • Bottleneck capacity must be resolved
  • Insight into operational performance
  • Reduce large inventories of raw materials and semi-finished product
  • Need to reduce setup times
  • Lack of skilled labor
  • Lack of continuous improvement

Quality

  • Must meet new compliance standards
  • Any variation in quality causes customer defection
  • New documentation and communication requirements
  • Tracking of material recipes by lot
  • Documentation for process and additional notes for different jobs and materials
  • Safety of materials
  • SPC, ISO, HACCP, FDA


+- WorkWise ERP Key Features for Rubber & Plastic Manufacturers

Mixed Modes

  • Make to stock
  • Assemble to order
  • Build to order
  • Configure to order
  • Repeat and tweak
  • Engineer to order

Mixed Methods

  • Lean Manufacturing
  • Kanban
  • MRP & MPS
  • JIT
  • 5s
  • MES
  • Role based manufacturing
  • TQM, Six Sigma, Kaizen

Manufacturing Execution

  • Visual scheduling
  • Shop Floor Control
  • Work in process manager
  • Asset utilization manager, CMMS/EAM
  • Mobile data collection
  • Kanban
  • Kaizen
  • 5s
  • Performance management
  • Human resources

Supply Chain

  • Inventory management
  • Available to promise
  • Purchasing
  • Bill of material
  • Engineering change orders
  • JIT

Cost Management

  • Actual cost
  • Job cost
  • Standard cost
  • “What if” costing
  • Multi-layered cost application

Production Planning

  • Material requirements planning
  • Master scheduling
  • Product configuration
  • Available to promise
  • Lot traceability

Customer Service

  • Quoting and estimating
  • Resin cost proliferation in costing and pricing
  • eBusiness and collaboration
  • Customer relationship manager

Quality

  • Engineering change orders
  • Quality control
  • SPC, ISO, HACCP, FDA
  • Supplier score carding


+- WorkWise ERP Software Additional Key Features & Functions

  • Role based ERP screens and applications
  • Back flushing
  • Bar code receiving
  • Blanket purchase orders
  • Customer collaboration portal
  • Shop order explosion
  • Matrix bills
  • Rule based configurations
  • Features and options
  • What if … quotes
  • Multi-level pricing
  • Smooth forecast error
  • Substitutes and alternatives
  • Family forecasting
  • Multi-level quotes and estimates
  • Serialized inventory
  • Plan vs. actual production reporting
  • Tool management
  • Document management for internal and external documents


+- WorkWise ERP Solution Benefits

  • Responsiveness to changing market demands
  • Ability to offer innovative approaches, products and prices for your customers
  • Control over the complex operations at every level
  • Improved efficiencies across all aspects of the organization
  • Manage the growing list of plastics in inventory
  • Improved costing of production runs
  • Extensive cost reductions (inventory, scrap, procurement) by integrating all aspects of the supply chain
  • Lower operational costs (errors, rescheduling, productivity)
  • Closely connected customer relationships and service
  • Leaner processes
  • Improved customer fulfillment
  • Higher quality
  • Reduced inventory costs
  • Monitor scrap and regrind for more accurate job costing
  • Shorter production cycle times
  • Streamline financial management processes
  • Strengthen customer relationships
  • Alerts to call attention to problems
  • Real time dashboards to monitor business wide performance
  • Monitor availability, performance, and quality
  • Automating the compliance process, and material certificates, ISO, HACCP, FDA
  • Manage the maintenance for all your equipment
  • Manage shelf life
  • Easy visual drag and drop scheduling
  • Pre-defined BOM’s
  • Easily handle resin cost changes in product costs and customer prices
  • Tracking lots for improved traceability
  • Matrix bills to lower part-nos. for colors, and other variables
  • Multi-level BOM’s to handle complex assemblies
  • Mobile bar code labeling and tracking for easy tracking

Ready to Learn More

Ready to see how our powerful ERP software can benefit your business? Schedule your personalized, one-on-one demo today.

Schedule a Demo

All aspects of our company are now running through our ERP software. Having everyone work out of the same system and not have multiple programs that you have to jump back and forth through, has allowed us to get more done in less time.

Gary Volz

Software Developer

ACI

One of the main benefits we’ve experienced using WorkWise ERP is being able to get meaningful information we can use, versus getting data that requires more work to get the answers you’re looking for. The data is integrated and streamlined for efficient use which keeps our fixed costs lower and allows us to invest our capital into building better products.

Michael Ray

CFO

ACR

It doesn’t take all day to do our schedule anymore. Also, the Performance Management WorkBench lets us see what information we want to see, and what time we want to see it, in a nice visual way. Item Planning is also great. It’s so easy to look up specific information related to whatever we need to see.

Kelly Crowell

AMI President

American Metal Fab

What’s really nice is having everything in one package. My financials are in the same package as manufacturing and customer orders. Everything integrates seamlessly. Bringing in inventory management has been a huge benefit for us. Being able to jump between workbenches and different points of data has been really nice.

Pam Reynolds

Chief Financial Officer

CapstanAG

I would highly recommend WorkWise to other companies. It’s cost competitive, the Cloud ERP implementation has been great, the people have been great. WorkWise bends over backwards to help us. We feel that they’re on our side.

Don Lavrenz

President and CEO

The Industrial Controls Company

WorkWise has been a true leader in our ability to drive process change and productivity enhancement, and to assist us in our lean capabilities.

Jim Moldenhauer

IT Manager

Hampel

I would definitely recommend WorkWise ERP to anyone looking to improve their manufacturing processes. We’ve been utilizing the software for 20 years and have never regretted our decision.

Chris Reid

President

Service Stampings

WorkWise spent a lot of time with us in order to understand our manufacturing process. We’re fairly unique, and there’s not that many companies in the world that do what we do. WorkWise really made us feel like they understood what we were doing and where we were going.

Dave Manahan

Business Process Improvement Director

Strongwell

The team at WorkWise is phenomenal. I highly recommend WorkWise ERP to any company looking to improve their processes, improve their efficiency, become more productive and work with a company who really gets to know them and understands what they’re going through.

Mike Campise

IT Systems Specialist

RMF