Software integration to improve business performance

Hayes International specialises in the design and manufacture of roll forming machinery for the production of roofing and wall cladding profiles, structural sections, long length power folding machines and a wide range of associated metalworking equipment. Hayes has developed a worldwide reputation for proven performance and high-quality machinery built in its modern facilities in Rotorua, New Zealand and Queensland, Australia.

Through a committed approach to innovative engineering design, dedicated focus to customer needs and total service, Hayes has become a world leader in the design and production of roll forming machines. Hayes machinery is found in more than 63 countries and 95% of Hayes business is offshore.

The company is constantly seeking to improve its manufacturing methods to achieve greater product performance and efficiencies for their customers. This is especially challenging because each machine is different. Hayes recognised its business needed to change in order to provide the desired level of customer service. Production capability was limited by trying to run its business with a variety of software linked together with manual processes including an exercise book used to record quote numbers.

Hayes chose Cogita together with Epicor Vantage in mid 2007 because of Cogita’s experience as an implementer of engineer-to-order ERP systems and especially its experience in implementing ERP systems in similar businesses to Hayes. The implementation project kicked off in January 2008 and is expected to go live in September 2008.

Alan Richards, Hayes manager of operations and assistant general manager says, “We have been using our TIMS system since 1996 and have built an Excel quoting and an MIS reporting system to fill the gaps. Even our financials are not integrated with manufacturing or purchasing. We know that we can do it much better than we are. Integration in Epicor’s Vantage ERP will make a huge difference to our efficiency.”

By using a system integration approach they have been able to implement an ‘Enter Once – Get it Right’ concept. The Hayes team is also looking forward to the next step, which is achieving complete integration between Vantage ERP modules and other software such as Microsoft Outlook. This will enable Hayes people to operate their ERP system Vantage without leaving Microsoft Outlook as if it was another folder.

Introducing one system to replace four disparate systems and many other manual processes will improve customer service by making quoting faster and more accurate. Because quoting is integrated with CRM, scheduling and customer information, Epicor Vantage provides Hayes with a CRM system with full facilities for opportunity management, marketing and call recording. Integration with Outlook will enable calls to and from clients to be dropped into the Vantage ERP system with ease. That will help Hayes to keep full client records within its backed up system rather than a salesperson’s notebook.

Graphical scheduling is expected to improve factory throughput by 25% with the ability to sequence jobs by due date, start date, project, operation or work centres. Accurate real-time costing using MES will help reduce waste and easy-to-use, low cost shop floor data capture terminals will help ensure that WIP is always up to date.

Stage two of the project will also involve the Hayes International facility in Australia and the implementation of the e-portal for online visibility by customers and suppliers. Stage three will involve implementation at other offshore facilities.

Cogita
www.cogita.com