Lad transferred Bulten Rus to 1C:ERP in two months

2022: Transition to "1C:ERP Enterprise Management 2.0"

The Corporate Projects team 1C Nizhny Novgorod IT of the company Lad implemented 1C:ERP for the company Bulten () for two months "Bulten Rus" , which is engaged in the manufacture of fastener parts for. automotive industry This was announced on July 22, 2022 by representatives of Lad.

When the customer faced the problem of import substitution of foreign, in ON a short time Lad managed to transfer the management of the enterprise to the system:. 1CERP

Fastener parts manufacturer Bulten found itself in a situation where the withdrawal of a foreign partner from the Russian market jeopardized the continuity of business and production processes. For several years, the company worked on foreign software, and its servers were located abroad. To continue the company's activities in normal mode, there was a need for an urgent transition to a domestic solution.

The Lad team had to study the business processes of accounting and planning of the customer and migrate from Infor M3 ERP to the 1C:ERP Enterprise Management 2 system on the 1C platform.

The customer had quite high requirements for the system. The following areas were subject to automation:

• Purchasing and Sales
• Production accounting built at the stages of the production process
• Planning of production schedule and shift-daily tasks
• Address warehousing
• Manufacturing and maintenance of tools and tooling for the production program
• Data Synchronization with Accounting

Key Project Objectives

The key tasks that needed to be completed when moving your enterprise to 1C:ERP:

• Transfer regulatory reference information for more than 8000 items
• Ensure end-to-end traceability at all stages and cycles
• Implement mechanisms for planning production and purchased materials based on residues
• Automate the work of the quality control service.

In accordance with the requirements of ISO 16949, it was necessary to ensure the traceability of lots of high-strength fasteners at all stages of production, so that in case of defects it was possible to identify the stage at which a failure in quality, technology or material occurred, and to recall the entire defective batch.

A feature of the project was that foreign software assumed fewer actions on the part of the user than a solution on the 1C platform, so the programmers were faced with the task of reducing the chain of operations to one action.

From the production point of view, the main task for the ERP system is continuity, which would allow you to quickly adapt working personnel and avoid errors and financial losses. I think we succeeded, - said Roman Sakharov, Operating Director of Bulten.

Project progress

The process of implementation using classical waterfall technology takes from six months to two years or more. In the current conditions, the Lad team had to retreat from the classics and work according to the Scrum method, distributing the volume of work to sprints.

{{quote "We divided the entire perimeter of work into processes that we understand, and those stages that are usually carried out sequentially, we conducted almost simultaneously: the programmer drew an automated workplace, the consultant-methodologist with the customer's representative worked out the logic and key requirements. After one or two days of development, they shared result - immediately corrected and sent to launch. Two or three iterations - and the working mechanism was ready for launch, - said Dmitry Izybaev, Lad project manager.}}

Thus, in two months, the Lad Corporate Projects team managed to restart the operational loop at the enterprise, ensuring uninterrupted operation. The management of Bulten Rus also notes that the functionality in the planning system has expanded, as well as the possibility of obtaining reports.

Key Project Results

The system has 14 specialized workplaces. For example:

• Work center "AWS Production" allows you to record the execution of production operations at each stage of the production process;
• At the Workstation "AWS Planning," all information necessary for making decisions on launching orders into production is consolidated. Auxiliary algorithms have been created that prompt a specialist in the planning and economics department to decide.

Each work center allows you to record one type of information at a time. This ensures that the data is correctly entered into the system. All related documents (orders, picking lists, roadmap, materials of specifications, labels for marking packages, etc.) are generated automatically, promptly and without errors.

The system accurately and promptly calculates the actual cost of each order, it became possible to calculate the order cost of production, taking into account the production of employees and equipment. 70% faster bonuses are calculated for employees of production and warehouse. The calculation of the price of products has doubled.

The end-to-end traceability of the products at each stage of production is ensured: the worker sees a task on the monitor at the beginning of the shift, scans the personal barcode and records the fact of raw material intake using the blank barcode. The system will not allow him to use the wrong grade of raw materials. At the end of the shift, the worker will hand over the parts, print and put into the container with finished products or semi-finished products a label with a batch barcode that reflects all information: item, worker, shift, quantity, weight. This barcode will be used by the worker already in the next technological operation. The whole further path of the part can also be clearly traced: at the quality control site, responsible employees form their own barcode with information about products for shipment to the warehouse, this is repeated throughout the production chain up to the shipment of products to consumers. This allows you, if necessary, to quickly identify the stage at which a failure occurred in terms of quality, technology or material, and to recall the entire defective batch.

The work of the quality control service is automated. The quality of incoming raw materials (its physical and chemical, as well as quantitative and qualitative indicators) and products are monitored at each stage of the technological process. The system allows you to identify the employee who performed the production operation, determine the date and time of the operation, and the quality control employee who confirmed the quality characteristics of the products. Previously, all these tasks were recorded "manually" in spreadsheets.

Management promptly receives analytical reports on the work of the divisions. 22 additional reports have been added to the system. For example, a manufacturing report showing the weight of the finished part (shows the stages of production, at which work center how many products are produced, the amount of scrap), tool consumption report (allows you to see how many materials are required to fulfill the order at each stage of production), coating report (shows the number of products sent for coating, the number of returned products and the number of products that the processor has), tool resistance analysis, etc.