integrate innovate succeed roadmap erproadmapsa.com/file/success_manatec.pdfestablished in the year...

MANATEC ELECTRONICS PRIVATE LIMITED

‘RoadmapERPfacilitated'ManatecElectronics'byitsagile

&innovativeintegrationprocess’

ROADMAP ERPSUCCESS STORY

Integrate Innovate Succeed

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MANATEC ELECTRONICS PRIVATE LIMITEDPONDICHERRY

AboutCompany

MANATEC is one ofAsia's largestOEMof automotive garage equipments. Located in Pondicherry, India, the

companymanufacturesWheelAligners,WheelBalancers,TwoPostLifts,Gasanalyzers,SmokeMeters,Headlamp

aligners&DigitalAirTirein�lators.

Established in the year 1987, as amanufacturer of industrial shaft aligners,Manatec diversi�ied into garage

equipment industry in 1991. The company, through its in-houseR&D, indigenously designed anddeveloped

Opticalwheelalignmentsystemsin1991,tobecomethe�irstcompanytodesignawheelalignerinthewholeof

Asia.

Manatec'sextensiveWheelAlignerinstallationsacrosstheworldspeakforitsquality,specializationandlead

roleweplayinthisindustry.

Wheel Aligners

Wheel Balancers

Two Post Lifts

Gas analyzers

Smoke Meters

Head lamp aligners

Digital Air Tire inflators.

NO.OFEMPLOYEES 200+ 2PONDICHERRY,INDIALOCATION PRODUCTSNO.OFUNITS

PAGE 01

“Roadmap team has done an excellent job in

meeting the extremely aggressive time-line for our

Business; we are highly pleased with their

performance and realize that, they have worked

roundtheclock,tomakethishappenforus.

We are very impressed with the ability to

deliverwhatwas promised, on budget,

andaheadofschedule."

ROADMAP ERPIntegrate Innovate Succeed

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PAGE 02SUCCESS STORY

ERP Selection ProcessIn 2006, MANATEC was looking for highly scalable, robust, cost effective ERP

solutions to meet its growing business needs. After evaluating several ERPs,

MANATEChaschosenRoadmapERPwhichhasmetallitsevaluationcriteria.

CoreobjectiveforimplementingERPisto,

Ÿ Integratebusinessprocesses

Ÿ Eliminateredundantdataentry

Ÿ Enable consistent planning of material, resources in production, sales, and

procurement

Ÿ Have effective control over every step of the operation, from purchase to

productionto�inaldelivery

Ÿ EliminatethetimespentbyeverydepartmentresourceforpreparingMIS

reportsinExcelsheetsandPowerPointpresentation

MANATEC used 4 d ifferent

Softwareapplications,tohandle

Finance,SupplyChain,Planning

& Manufacturing, CRM and HR

Functions and encountered the

followingobstacles.

NoIntegrationRedundantDataEntryReconciliation of data betweenmodu les was cumbersomeprocessManual preparation of MISreports which lead to mistakesandtimeconsumingNoeffectivecontrolLackofsearch-abilityLimitedfunctionalityInability to provide accuraterecords

Roadmap ERPwas planned to implement in 4Months period;

wherein,Roadmaphasinvolveditsseniormanagementtomake

theprojectsuccessful.Toachievethesuccessfulimplementation,

Roadmap Team has put enormous effort in all phases of

Implementationi.e.AS-IS,Gap-Fit,TO-BE,Design,Customization,

TrainingtheUsersetc.

Manatec follows 'Make-To-Stock' strategy. It prepares sales

forecast for the �inished goods and spares based onmarketing

teaminput;thereon,plansandpurchasestherequiredmaterials.

Production department produces the subassemblies, and

assemblesthe�inalproductthroughitsshop�looroperationsand

subcontractorprocesses.

Each Product Group contains multiple models and every

equipmentconsistsof1500to2000componentswhichneedtobe

accuratelyplanned,purchased,manufactured toassemble the

�inalproduct;andinwhich,30to40%ofthecomponentswere

interchangeable.

Requiredcustomizationsweredeveloped,tested&implemented

andTrainingprocessarecarriedouttoallmoduleusers;wherein,

thefeedbackwascollectedandaddressedontimelymanner.

IMPLEMENTATION

DIFFICULTIESDIFFICULTIES


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ROADMAP ERP

MODULES IMPLEMENTED

Financial Management

General Ledger Management

Accounts Payables Management

Accounts Receivables Management

Cash Management

Fixed Assets

Cost Management

Taxation

Sales & Distribution

Purchase Order Management

Subcontract Order Management

Quality Management

Inventory Control Management

Sales Order Management

Customer Relationship Management

Marketing

Customer Support

Planning & Manufacturing

Bill Of Material

Sales Forecast

Demand Management

Master Production Schedule

Material Requirement Planning

Shop Floor Management

Manufacturing Scheduling

HR / Payroll

Portfolio Management

Leave Management

Loan Management

Performance Appraisal

Payroll

Engineering

Implementation Challenges Codi�ication:SeparateItemCodehadbeenmaintainedfor

eachprocessinRouting.Classifyingandconvertingthemas

FGandSubAssemblyItemsand�ixingproductroutingtook

lotsofeffortandtime.

DataMigration:Anotherchallengewastomigratethedata

fromlegacysystemtoRoadmapERPSystem;inwhich,data

migrationofmastersandcut-offdatarequiredhugevolume

ofdatacleaning,andvalidation.

ShopFloorstagewisecompletionsneedtobetrainedtoShop

FloorUsersandtheywereverynewtoERPSystem.

Thousands of Materials need to be carefully planned and

procured.

Rawmaterials,BoughtOut,WorkInProgress,FinishedGoods

stocksrequiredtobeclassi�iedproperlyandmigrated.

S-ISA

GAP FIT A

NA

LYSIS

CN USOI TT OAZI M

ROADMAPERP


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ROADMAP ERP

IMPLEMENTATION HIGHLIGHTS

BENEFITSBENEFITS

Successful MRP: Foremost objective is to make MRP successful for vast spread

operations.Roadmaphadmadeitssuccessinshortestdurationandthereby,visualized

lotsofmateriallyinginWIP;witheffectiveInventorysystem.ProperInventoryenabled

tohavecompletevisibilityinmaterialstock,Planningandsubsequentprocurements.

Obsolete and Non–Moving Materials: Obsolete and non-moving materials were

identi�iedandcorrectiveactionsweretaken.

Trackingof sub-contractors stockofmaterial:Roadmap integration hadmade

successful tracking stock at Sub-Contractors; System enabled subcontracting

departmenttohavephysicalcountofsubcontractor'sstockandcompare&takethe

correctiveactionsforthedeviations.

DefectivesparesatServiceCenters,Fieldengineerswereindenti�iedandtakenfor

�ixingthesparesandmovedbacktotheSparesInventory.

ManagingMarketingActivities:ByRoadmap,Marketing&PromotionalActivities

werecarriedintimeandtheprocessofenquiry,customerrelationship,quotationsand

delivery weremade easier. System accuracy enabled insight view of the activities

prevailinginthemarketwhichenhancedtotakeprudentdecisionsintime.

Follow-up of Equipments AMC: Systemmade possible to provide triggers for all

pending,expiredandduesinrelatetoAMCSupport.Instantgenerationofinvoiceswas

madeeasierandlesstimeconsuming;througheffectiveviewofcustomerrecords.

Roadmap System gone Live within 4 Months of time by implementing & integrating all core modules; in which, submitting project plan, simultaneous support with existing operations, importance to customization & System Live were all done within the scheduled period of 4 months.

MANATEC has given excellent cooperation in all phases of project Implementation Process. Project review meetings, workshops were conducted time to time; wherein, all feedbacks, requirements received from module Users were considered and addressed on time.

Training process were organized to explain the functionality and thereby ensured operational excellence at user levels.

By means of having timely cooperation from MANATEC, the project was able to accomplish within the stipulated time frame.

SCALABLE

EFFICIENCY

CONTROL


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ROADMAP ERP

Support toTradingActivities:TomanageTrading businessmore effectively and

ef�iciently, Roadmap had proposed a best �it suite to address areas such as Sales

management, Customer Relationship management, Easy purchases, warehouse

handlingandstock&inventorymanagementetc.

Time-consumingeffort to �indchangehistories:Foundhard toaccomplish jobs

whichneedstobeaddressedintimeandofaccuracyinoperations.Roadmapenabled

thesystemtogetintothestrategicstandardsintimeandhelpedtotakemanagerial

decisionatrighttime.

BetterVisibility&Control:Bettervisibilityintoproduction&warehouseoperations,

inventorylevels,stagewisestockinshop�loorandwithsubcontractors/suppliers.

ReducedDataEntryProcess:Automatedprocesseliminatedredundantdatare-entry

whichsavedlotsoftimeandenergyatdifferentlocations

Work�lowbasedapprovals:Properwork�lowbasedapprovalsensuredrightperson

authenticatingthedocument.

ImprovedPlanning:Completeassistanceforcomplexplanningandtherebyenriches

forecastingcapabilities.

Traceabilityofrejections:Ateverystageofinspectionprocessi.e.MaterialInward,

ShopFlooretc.therejectionswereidenti�iedandprecautionarystepsweretakenfor

betterusageofMaterial.

SubcontractorsProcesshandlingmadeeasier:Systemmadeeasytosendmaterial

to subcontractors for single ormultiple processes and enabled to receive partially

processed,fullyprocessedandunprocessedmaterialsandadjustthedeliveryChallan

quantityaccordingly.

Post Sales Service: Establishment of online service capability forwarrantymade

mucheasierwithenormouscustomreportsintime.Providesbettercustomerservice

throughimprovedinventorycontrolandstockholdings

Improved Customer Satisfaction: Through easy contact management, customer

satisfactionisensured.

TimelyReportingStructures:Better,fasterdecisionmakingwithtimelyreporting

structuresavailableinsourcemadereportingeasier.

UpgradedSysteminplace:Supportsforlong-termgrowthbyinnovativeand

upgradedsystem.ERPprovidesastate-of-the-artintegratedmodulesetdelivering

strongaccountingand�lexiblemanufacturingfunctionality.

BENEFITSBENEFITS

No. 5, Republic Street | Reddiyarpalayam | Pondicherry - 605 010 | India Phone: +91 413 420 7333Email: [email protected]

www.roadmapit.com


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RoadmapITSolutions(P)Ltd.

SUCCESS STORY

CorporateOperationalOf�ice:No.4,Akshaya,IstFrontBlock,VysyaBankColony,SarakkiMain,JPNagar1stPhase,NearRajlakshmiHospital,Bangalore-560078.Ph:9663308001

RegionalOf�ice-Chennai:No.11,FirstFloor,SamiyarGardenStreet,AshokNagar,Chennai-600083.Ph:+919442510123

RegionalOf�ice-Coimbatore: Old.No.20,NewNo.39,VinayagarKoilStreet,1stFloor,KrishnasamyNagar,Coimbatore-640045,India.Ph:+919442580742

RegionalOf�ice-Mumbai:AnmolPlanetBldg.,Of�iceNo.5,Plot.211,Kopra,Kharghar,NaviMumbai-410210,India.Ph:+919930305054

RegionalOf�ice-Baroda:ShopNo:23,UpperGroundFloor,SilverRockComplex,Bhavan'sSchoolCircle,Vadodara-390004,Gujarat,India.Ph:+917698695109

OverseasOf�iceMiddleEast:ZaitunahCommercialCenter,Of�iceSuit#205;BldNo.7097,Jeddah-23343-3523,KSA.Tele/Fax:+96612613381

Europe:FidelitasSA,15,ruedeCendrier,1201Geneve,Switzerland.Ph:+41793755566.

Africa:7TroonCresent,SilverLakeGolfEstate,Pretoria,SouthAfrica.Ph:+27610807322.

SriLanka(PartnerOf�ice):ProvidenceGlobal(Pvt)Ltd,752/1Dr.DanisterdeSilvaMawatha,Colombo09,SriLanka.Ph:+94768373971

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