What We Do  

We can perform the following services for your organization:

• Operational Reviews
• Implementation of Material Requirements Planning and MRP2 Systems
• Development of Training Courses
• Software Systems Requirements Definitions
• Manufacturing Cost System Design, Analysis and Review
• Data Processing Systems Design and Development
• Software Package Evaluation and Implementation
  

Operational Reviews:

We have performed in-depth review of the functional areas of a number of manufacturing organizations. The purpose of these reviews has been to determine if the company is conducting its business in an efficient and effective manner. For example:

In one company we found that although the company had installed a computer- based information system, the employees were not making effective use of the computer resources. They did not understand system actions in response to their inputs and the value and use of the various management reports. We worked with the company to identify and provide the training necessary for their employees to obtain the full benefit from their computer systems.

In another company, missed delivery schedules and component parts shortages were due in part, to a lack of bill of material accuracy and control of the engineering change process. The development of formal procedures for engineering changes and the establishment of regular meetings to review and implement engineering changes improved accuracy of the bills of materials and ultimately reduced shortages which led to improved delivery performance.

We have been successful in identifying opportunities and in proposing solutions to problems resulting in an improved ability to manage the company effectively. Some of the recommendations we have made have allowed companies to receive the following benefits:

• Reduced rework and scrapped material resulting from improved communication between engineering and production.
• Improved ability of material and a consequential reduction of work in process inventories through greater visibility of material requirements.
• Reduction of working capital requirements through proper use of material planning systems.
• Use of forecasting to permit a reduction of finished goods inventories while improving customer service.
• Improved security of data processing systems and corporate records.

MRP and MRPII Systems:

We have implemented manufacturing systems in a number of environments: job shop, repetitive, and process oriented operations.

For a manufacturer of electronic products we assisted in the re-implementation of a material requirements planning system. The company was not operating the system in a manner which enabled it to obtain the expected benefits. We diagnosed the problems and developed and directed a plan to help them get back on track.

We provided assistance in the installation of the stores management phase of a material requirements planning system for a multi-plant electronic controls manufacturer. We provided direction and advice in the physical layout of the warehouse and the transaction control center, the development of operational policies and procedures and the use of the software system being installed.

For a manufacturer of machine tools, we assisted in the installation of Inventory Management and Product Structure Definition modules of a Material Requirements Planning System. Prior to our involvement, the company had spent over a year in an unsuccessful attempt to properly define their bills of materials and construct their data base. With our assistance, the company was able to implement these modules within a four month period.

For a manufacturer of capital equipment we directed the conversion to a new integrated MRP II system. The old system was not integrated between functional areas and was not fully utilized. We planned the conversion, developed conversion routines to load the new data base. We developed an education plan and conducted education on MRP systems and the application of the new system to the company's environment. We provided training to individual users and directed the development of new operating procedures.

For an industrial equipment manufacturer, we performed the system design, identified and assisted in the resolution of system implementation issues, assisted in the data base conversion effort, provided general manufacturing systems education and served as liaison between the client and the software vendor.

Development of Training Courses:

We developed a training program for inventory and stores management personnel for a large electronics manufacturing company to be used in an in-house employee education program. The training program integrated standard practices with the existing procedural and data processing systems environment. This approach permitted employees to be taught proper methods in a manner tailored to their specific environment.

We developed a training course on the use of a new General Ledger and Responsibility Accounting System for a metropolitan transit authority. The training course introduced new concepts for analyzing and controlling expenditures.

We developed and presented a course on the use of computer-based tools to audit information systems for an industry trade group. The course material we developed presented new approaches and techniques which would allow internal auditors to verify the integrity of the data in the system and support external auditing requirements.

During the course of a new MRP system we tailored standard educational training materials to the client environment creating examples which utilized both current and new forms and reports to provide users with a better understanding of how their jobs would change with the new system and what new procedures and policies were to be implemented.

We developed a company-wide Education Plan for a company in conjunction with the implementation a new manufacturing system. A curriculum of courses were developed based on the results of an education and training needs assessment survey that we developed, adminstered and analyzed. Ten functional areas were identified and a curriculum was developed for each area. Courses were selected from a standard library educational materials. Individuals were selected for one or more functional areas based on their job function and the areas that they interacted with most frequently. Schedules were developed for each training group and group leaders both were identified to serve as facilitators.

Software Requirements Definitions:

For a specialty printing company we developed specifications for an accounting and shop floor scheduling system. These specifications permitted the client to evaluate their present system in light of their real needs and to select a system appropriate to their environment.

For a distributor of commercial building hardware, we specified the requirements for a customer order processing system. This system made extensive use of family bills of material and the use of generic part numbers to reduce the total number of product structures down from over 6,000,000 to under 5,000. We developed the user documentation and trained client personnel in its use.

For a multi-unit group of a diversified international corporation we performed a manufacturing system requirements definition to identify a single system which would best fit the needs of each company in the group. The requirements of each company in the group were analyzed individually and collectively. Our approach, which utilized our proprietary software to analyze the requirements allowed the corporations to quickly identify software packages which would meet the collective needs of this diverse group of companies.

Manufacturing Cost System Design, Analysis and Review:

For a manufacturer of automotive fasteners, we performed an review of their manufacturing cost accounting system to determine the cause of a recurring year-end book to physical inventory discrepancy. We identified areas both in manual procedures and in the data processing programs where these discrepancies could have arisen. Our recommendations allowed management to identify the causes and take corrective action.

We developed a standard cost accounting system for a manufacturer and distributor of construction testing supplies. This system permitted the company to monitor and more quickly respond to changes in their costs for both purchased and manufactured products. This system allowed them to maintain profitability by highlighting changes to inventory gross margins.

We performed a requirements definition and analysis of financial/job cost accounting software for a research and development firm. Our analysis allowed the company to acquire a package which would serve both their financial and government project cost accounting needs.

As part of a corporate audit we verified modifications made to a standard manufacturing package to perform actual FIFO costing to track specific costs to products as they flowed through the job costing structure. Our analysis verified the proper operation of the code which performed the cost accumulation and reporting processes.

For a specialized printing company we performed an analysis of their pricing policies and the cost structure of their operation. We used the costing structure to review the profitability of actual jobs for various types of work. Our analysis showed the company how to revise their pricing structure to improve profitability.

For an electrical component manufacturer, we developed a model to assist in the phased annual profitability plan. The model, based on marketing forecasts, planned stocking levels and patterns in cost relationships, provided P & L, cash flow, and balance sheet outputs. Additional outputs provide for capacity and manpower planning.
In conjunction with this project, we provided services as interim controller while the company was being prepared for divestiture to another company. Included in our responsibilities were monthly financial reporting, consolidation, analysis of accruals, and special cost related projects.

Data Processing Systems Design and Development:

For a government electronics manufacturer we design and implemented a computer based material control system. We performed the system design, programming, testing, and documentation of the system, and managed the implementation. The system encompassed the areas of inventory control, product structure definition, material requirements, purchasing, and project cost estimating. The system enabled the company to plan their contract material requirements, control their inventory, monitor status of purchase orders, and effectively bid on manufacturing projects.

We developed a financial consolidation system for the central office of a large diversified corporation. The system permitted the corporation to construct financial statements in various formats at all levels of the corporation. This capability enabled management to better analyze monthly financial data for the various operating entities.

For a steel fabricator, we designed an automated design and drafting system. This involved the application of specific design criteria and geometric configurations, and the plotting of the resulting design on a large drum plotter. Included as part of the plotted drawings were bills of material of the major structural members derived from the structural design. As part of the plotting segment of the system we also developed a library of graphic subroutines.

For a tool manufacturer we designed modifications to a standard manufacturing software package to customize the system operation to their unique manufacturing process. Their manufacturing operation was driven by a multi-level routing/co-product orientation rather than the more traditional bills of material/work order driven environment. Our modifications permitted the company to retain the simplified reporting capability of their old system and as well as provide improved cost tracking within the new system environment.

For a manufacturer of environmental controls we developed an system to configure and generate reports from data collected by their controllers. The system was written in Visual Basic for Applications and runs in both attended and scheduled modes. Data can be collected and reported on based on user specified periods for each report. Reports calculate energy consumption and alarm conditions and durations with several levels of aggregation of data.

For a distributor of industrial chain we developed an order entry and invoicing system, and forms processors for Credit Memos, Purchase Orders and Amendments, andQuotations. The systems includes a customer data base and several status reports a generated by users.

For a manufacturer of bulk solid conveying equipment we developed a multi-user system utilizing Visual Basic for Applications for calculation of gross margins utilizing complex proprietary algorithms for determining each factor. The system provides a centralized data base as well as a local database for off-site use.

For this company we also developed a multi-user Sales Information System which processes quotations and orders and produces a number of management reports.

For a manufacturer of building automation controls we developed a system for laboratory data collection and reporting to satisfy OSHA reporting requirements on laboratory fume hood operation.

For this company we also developed a building operations management reporting system to identify energy resource usage and waste.

For this company we also developed a building operations management reporting system to identify energy resource usage and waste. We developed data collection software the operated via modem and over the Internet. The software parsed the data and monitored the quality of the data using a finite state approach to cleanse the data so that the analysis portion of the system operated on only “clean” data. The data was stored in a SQL based data warehouse of millions of records and was over 50 GB in size. Data was partially summarized as it went into the database and we made use of Crystal Reports to generate reports and graphs from the data. We were issued a patent for a technique for ranking weather quality and accuracy. The weather data was an important part of the energy forecasting that was a key component of the overall system.

For a manufacturer of food additives we developed a system for Sales and Commission Reporting. This system interfaced with the existing business system and provided custom sales/commission allocations and provides the ability to track, report and forecast sales based upon the long term data collected.

Software Package Evaluation and Implementation:

We have worked with a number of software packages over the years, from the standpoint of evaluation of the package for a particular company environment, conversion from, or in the direct implementation of the package. We have specified modifications to tailor the package to the client environment and worked with the software vendor to make the changes for the client.