Page 32 - MetalForming July 2019

Fabrication: ERP
A monitor hangs in the TOA USA maintenance department listing any open work orders, including open duration and who is assigned to the work order.
reducing workforce and forklift costs related to material handling.
• For the first time at TOA USA, all data reside in a single database. Storing data in the same structure assists in locating it and helps TOA USA move toward a single version of production and operation reality.
Quicker Data Access, Greater Visibility
Unlike prior to the new ERP imple- mentation, production reporting now is a real-time reality. Downtime, scrap and more begin recording as soon as a machine or cell starts, with inventory adjusted immediately upon production of each container quantity. Real-time capability delivers the ability for super- visors, engineers and others at TOA USA to quickly assess production, inventory and other issues, with alerts sent immediately to designated recip- ients. And, from the data, reports can be created to provide issue assess- ments, trends and more. All of this enables quick action. Perhaps most importantly, employees can act off of full, accurate data to better address issues and plan ahead.
“With real-time reporting and the alerts, we can react immediately instead of finding out the next day about an issue that occurred yesterday or last week,” explains Bob Whyte, TOA USA vice president of operations and quality. “And, instead of waiting weeks or a month, we can access reports, including trends, when we want them. That’s a big change, making us all more effective.”
Accessing the information and entering data also is more controlled via the ERP upgrade. For example, prior to the upgrade, generic user accounts provided no visibility into who was adding or changing informa- tion, and why. Now, each user has a unique account, which has bred the input of more accurate and detailed information.
“Not only are we intentional when making adjustments, but we are inten- tional in our documentation, which has led to more comments in the sys-
they can employ on the floor to better understand the production situation.
• Just in Time (JIT), critical in TOA USA’s warehousing and shipping, places scheduling demands related to raw materials and other supplies com- ing in the door, to stamping presses, to welding, to assembly to shipping
products out the door. In addition to leveraging real-time monitoring, TOA USA uses work-center inventory track- ing to JIT-move inventory into work centers. The company also uses auto- matic guided vehicles to deliver the inventory to cells. Together, these approaches address JIT demands while
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30 MetalForming/July 2019
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