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Metal fabrication is an exhaustive process that includes a multiple-step process, such as timely procurement of raw materials, managing the manufacturing workforce, adhering to strict deadlines, handling bottlenecks, and many more. Here is a list of challenges that your business will face quite often:
Metal fabrication manufacturing companies deal with resource planning, including controlling scraps and wastage. Studies show that ERP for metal fabrication can help companies save about 30% of the cost of the finished goods, but many of them are unaware of this benefit.
The forging process is lengthy and contains multiple levels. The lack of a manufacturing ERP results in companies losing a lot of time and resources during the forging process.
Managing and controlling job work and its associated costs is a headache for most companies.
Companies must focus on managing subcontracting operations and find ways to decrease manufacturing costs.
Monitoring foreign currency and exchange rates, variation in raw materials prices, and multi-currency exchange gain and loss is a challenging area for most companies.
Estimating the demand and supply of finished products and forecasting customer demand is a complex area to deal with.
Metal fabrication software is ideal for your business as it will provide you numerous features to become a top performer. Here are some of them:
ERP for metal fabricators helps in materials requirements planning. First, this feature ensures that essential raw materials are always available in the inventory so that the production process goes unhampered. Secondly, it has a master production scheduling module that optimizes the production process, identifies bottlenecks, and anticipates the number of products required in the market based on customer needs.
Manufacturing ERP software for the metal fabrication industry has a visual scheduling feature that allows managing work center capacity, monitoring skilled labor and material availability, and checking tooling constraints from one place.
Enterprise resource planning software allows metal fabricators to collect the exact cost of labor and materials and other overhead charges. This feature helps estimate the selling price with margin transparency.
Sage metal fabrication ERP software is the best-in-class as it offers powerful tools to manage business operations smoothly. In addition, the production management features of this software will enable you to craft precision-cut machinery that will stand the test of time. Here are the essential elements of our metal fabrication ERP software.
Time-to-quote is an essential component that either makes or breaks customer deals. ERP software allows you to significantly decrease the time-to-quote by helping you arrive at your cost estimates in the least time possible. In addition, you no longer have to depend on spreadsheets, papers, and pencils. Instead, you get real-time visibility about your inventory, bill of materials, multiple vendors, profit margins, customer preferences, and much more.
Metal fabrication companies work on simultaneous orders that differ in dimensions, specifications, and quantity. ERP software has nesting applications that simultaneously manufacture numerous products while ensuring minimum wastage of materials, minimizing inventory costs, and triggering re-ordering, if necessary.
ERP software keeps a check on the entire supply chain, from raw material procurement to the delivery of finished products to consumers. You can track the real-time location of inventory in the warehouse by generating bar code labels. Also, purchase managers get automated alerts about the exact levels of raw materials that allow them to place orders for materials that are below the set threshold. This module optimizes the inventory levels that substantially reduce storage costs.
Two of the most challenging areas for metal fabricator organizations are material management and scheduling. It includes getting the right raw material at the right time, producing the right product at the right time, and delivering the right product to the right customer in the shortest possible time. The Material Requirements Planning (MRP) feature of ERP software identifies material demand, triggers purchase orders, and optimizes inventory levels by analyzing the demand and purchase trends. Thus, your warehouse will never be over-stocked with materials that you don’t need, which will help you save a significant amount of money.
ERP software can be modified conveniently, which is one of its most incredible benefits. In addition, there are various applications such as e-Commerce, Electronic data interchange (EDI), test equipment, and machine controller that complements ERP system’s functionality and provides massive benefits to users. You can also integrate CAD systems that route design changes to nesting software such as SigmaNest and ProNest for rapid production.
Metal fabricators provide end-products to industries, such as aerospace, automobile, machinery manufacturers, that demand top-notch quality standards. The quality management and control module ensure that high-quality standards are maintained at each step of manufacturing. The Manufacturing Execution System (MES) creates checks and balances that monitor quality parameters at each stage and take corrective measures in case of defects. In addition, product traceability features like bar-coding allow quick recall of damaged products that help improve customer relationships and market reputation.
Here are a few quick points that tell about the opportunities that this sector has in the future:
Forecasts suggest that the metal fabrication industry in India is expected to grow at a CAGR of 5.5% from 2020 to 2025. Experts suggest that this industry will grow from USD 16 billion in 2015 to USD 24 billion by 2024. Significant rise in automotive production and infrastructure development and growth expectations for the commercial and residential building industry are strong indicators that the metal fabrication industry will rise rapidly. In addition, government initiatives and policies like the granting of mining lease of Utkal-E coal block in Odisha to National Aluminium Company in April 2021 show that the government is taking necessary steps to improve the production of metals in the country. Also, private companies like Vedanta have signed MoU with Indian research institutes to find ways to create value from bauxite residue.
The future is bright for the metal fabrication industry based on the cumulative amount of investments and technology development in this sector. Here are two significant points that will pave the way for this industry in the near future.
The role of automation is significantly increasing across each industry. It allows companies to reduce their dependence on their workforce, eliminate human-induced errors, and save time and money. And the same holds for the metal fabrication industry as well. Automation has helped accelerate production, facilitate supply chain management, and automate processes such as cutting and bending heavy metal sheets without human supervision.
3D printing is no less than a boon for the metal fabrication industry. The following example illustrates why. Previously, steel manufacturing industries had to build giant structures step by step. But with the help of 3D printers, they can make massive structures and install them in one step. This step helps save valuable time and money.
The metal fabrication industry is characterized by large-multi component assemblies based on customer specifications. The primary operation in this industry is assembling mechanical parts that require a lot of accuracy and precision. You need ERP software for the metal fabrication industry for various purposes like generating a bill of materials, monitoring stage-wise processes, quality control processes and inspection by third-party vendors, managing shop floor activities, and ensuring that the entire manufacturing process is smooth. ERP software for the metal fabrication industry provides the following benefits:
Critical information regarding products, processes, vendor relationships, customer demands, and other essential records are stored in a single repository accessible to relevant stakeholders anywhere and at any time.
Reduces operational costs by decreasing delays in operations and eliminating errors in processes.
Each financial transaction of your business is recorded and stored safely in the ERP software.
The inventory management module keeps track of each part, raw material, equipment, and finished product. Moreover, it also ensures that manufactured products are stored at appropriate places to be loaded onto the supplier’s trucks at the earliest.
The business intelligence module analyzes the changing market preferences and customer trends and provides recommendations on what products have the highest selling potential.
The supply chain module of the ERP for the metal fabrication industry ensures proper coordination between various stakeholders, including the company, vendors, suppliers, distributors, and customers. It also identifies the bottlenecks and sends a detailed report to the respective manager.