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Sescoi’s Myworkplan job management software has improved the way in which Kraftsman Tooling, based in Pune, India, manages the manufacturing of its plastic injection moulds.

Kraftsman Tooling specialises in the production of moulds for automotive companies including Tata Motors, Tata Autocomp Plastic Systems and Minda Valeo.

The company also offers engineering services for product and mould design and moulding feasibility analysis.

George Joseph, managing director, said: ‘We needed a more systematic approach to managing our quotations, the progress of manufacturing and the ongoing costs of our tools.

‘Previously, we were using spreadsheets, which made it very difficult and time consuming for us to keep track of costs and events,’ he added.

Myworkplan can import existing data so that knowledge and experience built up over the years can be incorporated into the system as historical data.

The quotation module in the software is able to draw on this information as well as the latest cost and time data accumulated from new jobs processed in Myworkplan, enabling highly accurate quotes to be produced in just a few minutes.

Joseph continued: ‘We can look up similar quotes and check on our performance when the job was manufactured, allowing us to anticipate likely problems and incorporate the cost of the mould base or any side cores or lifters and estimate the machining costs for each element of the tool.

‘Menus guide us through the system, ensuring that we have not missed anything, quickly generating an accurate cost for the whole mould,’ he said.

Once the quotation turns into an order, the data built up in the quotation stage of Myworkplan is transferred into the scheduler, where more detailed planning takes place.

This considers the human and machine resources available, allowing the company to arrive at a realistic delivery date and a schedule of the necessary work required to finish the job.

Myworkplan also enables the company to have a snapshot of the current status of production in real time, tracking the progress of each job, employee time and attendance and the ongoing costs of manufacture.

Joseph said: ‘We can compare actual performance with our budget.

‘The scheduler generates job sheets detailing what each machine needs to do in the next shift and forecasts the hours required for each operation.

‘Feeding back the actual events into the system as they occur allows us to check that we are on target with our cost and delivery objectives and take appropriate action to correct any deviations from the plan at our daily progress meetings,’ he added.

Before the implementation of Myworkplan, Kraftsman Tooling was concerned that installation and training would take up too much time.

However, applying Sescoi’s Fast Start implementation methodology, the quotation module of Myworkplan was first installed, followed by the job tracker and then the scheduling modules.

Phased installation allowed the company to get to grips with the software and build up expertise.

Joseph said: ‘The screens are intuitive and the software is easy to use and includes tutorials to cut the learning curve.

‘Documentation for every aspect of the job is stored centrally and is now at our fingertips.

‘It has given us a 35 per cent time saving running the business, leaving us more time to spend on other tasks,’ he added.

The company can now give its customers more accurate delivery dates and can ensure that they are consistently met by utilising the automatic alarms, which give warnings when tasks are delayed, and the resource loading list, which helps Kraftsman Tooling to manage its workshop loading, improving customer satisfaction.

Accurate quotations ensure that realistic prices are being quoted.

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