ERP SOFTWARE

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 VARIETY

GROWING COMPETITION

INCREASING CUSTOMER DEMANDS

HIGH DEGREE OF FLEXIBILITY

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.