Manufacturing performance boosted with K3s Micross ERP software

Citation

(2003), "Manufacturing performance boosted with K3s Micross ERP software", Aircraft Engineering and Aerospace Technology, Vol. 75 No. 2. https://doi.org/10.1108/aeat.2003.12775baf.012

Manufacturing performance boosted with K3s Micross ERP software

Manufacturing performance boosted with K3s Micross ERP software

Keywords: Software, Manufacturing

It is reported that a sustained investment programme in computerised manufacturing management systems has resulted in British-owned aerospace company APPH Limited reducing manufacturing lead times by half, doubling its number of stock turns and cutting headcount and inventory.

APPH has so far implemented K3 Business Technology's Micross for Windows Enterprise Resource Planning (ERP) software in four of its eight sites in Britain and the US. The software handles the company's manufacturing requirements for both make-to-order for original equipment and make-to-stock for aircraft spares.

The company's services cover initial concept through final design, manufacture and lifetime engineering support. Its products include landing gear systems, flight controls and hydraulic system assemblies for both civil and military aircraft, and filtration equipment. Almost every engine ever built by Rolls-Royce carries APPH filters. Other facilities include high precision machining and independent repair and overhaul companies.

Cellular manufacturing techniques are used for the assembly and testing of all hydraulic equipment. These include a clean-room environment for safety-critical assemblies and those that demand ultra-high precision. Typical batch sizes range from 1 to 25. The company has a turnover of $100 million and employs 450 staff.

APPH numbers the top aerospace companies in the world amongst its clients, and current programmes include flight control and landing gear systems for BAE Systems Hawk and C27J military transporter, and hydraulic systems for the Raytheon Hawker 800 business jet.

The company has received a number of awards for its continuous improvement and lean manufacturing initiatives, including a BAE Systems award for Supply Chain Excellence.

In 1989, APPH identified a need for a flexible computer system for its Bolton site. A key requirement was for a package solution rather than bespoke software; it also had to be cost-effective, user-friendly and be operated without the use of computer specialists.

"We chose Micross," says APPH Managing Director David Haslam, "because it met all our selection criteria. From our decision to buy until the system was up and running took 6 months, although we have almost halved this time with subsequent implementations at our other sites. Timescales have to be very aggressive, otherwise you tend to forget the original objectives, key people leave the company and, generally, the impetus is lost."

"In 1994 we expanded the system to our Runcorn site with similar success. As we were eager to embrace the growing benefits of windows technology we were one of the first companies to adopt the MICROSS For Windows (MFW) system in 1998. We chose the Bolton site as the lead implementer and it took us about 4 months We invested heavily in education and training. It is essential that staff take ownership of the system, so there must be extensive training to change the company culture. I also think active participation in the user group is essential for generating feedback and providing a discussion forum.

"At the Runcorn site we have seven Linvar Paternoster storage machines for stockpicking which have been interfaced to MFW. This has greatly increased the efficiency in part picking and stock management. This year we have also implemented the system at TRAK, our high precision grinding assembly facility. The system's production control module is particularly relevant for the company's multiple machining operations. Our Airight Inc. subsidiary in the US is also implementing MFW."

K3 Business Technology's MFW is a 32 bit system comprising over 30 modules that grow together to provide a fully integrated ERP system on Windows and Windows NT platforms. APPH sites typically use MFW modules such as sales and purchase order processing, inventory, bills of materials, MRP and financials. The system caters for a wide variety of manufacturing environments. APPH, for example, has a complex Bill of Materials: the average landing gear strut has 400 items and over 3,000 for the complete landing gear system.

"The benefits of the system are numerous," says David Haslam." Generally speaking, you tend to work smarter when you put a computer system in. The systems have reduced manufacturing lead times by half, they handle our material and parts traceability requirements and, basically, they help keep our headcount down. Inventory has also been reduced and stock turns have doubled. This is important to us because if just five of any aircraft type are still flying anywhere in the world we have to carry a base level of spares for support."

MFW has an open database and APPH uses its inbuilt Crystal report writer for standard management reporting, and an Access database for special reports.

The company is standardising its networks systems, and hardware platforms are all NT. An Intranet is used across the company and information can be exchanged between the sites. It is also linking its engineering systems. APPH's design and stress engineers work as an integrated team for each project. A good example of this is the programme for the Saab JAS 39 Gripen Advanced Combat Aircraft, where APPH designed, certified and manufactured the entire landing gear system including struts, actuators, the electro hydraulic selector and steering control valve. So electronic data exchange is already carried out between the Unigraphics and CATIA computer-aided design systems and stress analysis programs.

In addition, the company is moving towards document management systems and a paperless environment. "We are also linking Unigraphics and the IMAN product data management system to MFW," says systems manager Andy Treadwell. "IMAN is a product lifecycle management system that basically stores product data and information and handles related changes. The integration between IMAN and MFW will be at the Bill of Materials level."

David Haslam adds, "Our vision is to have state-of-the-art, integrated systems right across the company, and we are also providing links to our supplier base as well as receiving orders from our customers around the world." He sums up a key benefit of MFW in one word, "Visibility. By making a few key strokes I can find out what I want about our customers immediately."