Friday, November 6, 2009

Unexpected Benefits for the Aftermarket

Jacobson talks a lot about what he calls SAP vanilla the basic functionality of the software that is available immediately, without configuration, right out of the box. What I really appreciate about SAP vanilla, Jacobson says, is the companystructure piece. You set up relationships among entities within the organization all very explicit but flexible at the same time and thats the core benefit. In fact, its an ongoing benefit because its given us the flexibility to adapt quickly as our organizational structure has changed.

Universals ability to model and flexibly manage its organizational structure within the software delivered some unexpected business benefits as well. Jacobson explains, We originally implemented [the software] to get a handle on our core business financials, ERP, that sort of thing. The structure SAP [software] gave us really helped kick our aftermarket parts and service business into high gear. And thats extremely important because that business is high margin. It really became the poster child for the success of the SAP implementation throughout the organization.

Universal Instruments aftermarket business operates on a direct-service model. This means the company itself maintains direct control over operations, whereas competitors may outsource the job to distributors. It keeps us close to the customer, says Jacobson. And it gives us a lot of credibility during the sales phase because we can make promises about service levels that our competitors cant really make due to the fact that they dont have direct control over their aftermarket operations.

Before implementing SAP software, Universals aftermarket business was profitable, but inventory carrying costs continually ateinto margins. We had depots all over the world with parts just piling up, Jacobson explains. But now, with our SAP software, we have so much more visibility. If a customer needs a part, we can get it to almost any place on the planet within 24 hours. And we can do this with lower overhead because now we have the power to forecast demand.

Previously, it would have required a major undertaking to adjust our plans. But now, its just trivial just press a few buttons. Instead of the mechanics of how you change a plan, our focus is on what the market is doing and how this impacts our business strategy. What used to take about 80 work hours a month now takes minutes.
Jim Jacobson, Director of Information Technology and System Software, Universal Instruments

In fact, Universal has been able to reduce cycle times by 30% to 40% and significantly increase inventory turns. This has really given us a market leadership position in the aftermarket business, Jacobson says. And, you know what? It also helps us sell our machines in the first place. Customers need to know that youre going to be there when they need you, and, in very unambiguous terms, we can demonstrate impeccable service capabilities and a clear record of customer satisfaction.

SAP Customer Success Story: Industrial Machinery and Components

The structure SAP [software] gave us really helped kick our aftermarket parts and service business into high gear. Jim Jacobson, Director of Information Technology and System Software, Universal Instruments

Universal Instruments is one of the worlds leading electronics productivity specialists, providing innovative circuit, semiconductor, and back-end assembly technologies as well as equipment, integrated system solutions, and process expertise to manufacturers in every sector of the global electronics industry. Universal Instruments is a global company with approximately 1,200 employees; manufacturing facilities in Shekou, China and Binghamton, N.Y.; and offices in 21 countries. But it wasnt always that way.

In the 1990s, things changed for us fairly rapidly, says Jim Jacobson, director of information technology and system software at Universal. In a matter of two quarters, our business was in China. We became a global company.

But there was a problem. The company didnt have the processes to sustain its new business model. Expansion and acquisition resulted in an amalgamation of systems and processes that failed to scale in a way that could accommodate the companys emphasis on business agility in a global market.

In the mid-1990s, Universal decided that something needed to change. Thats when we took a look at SAP, says Jacobson. Basically, we decided to scrap our legacy environment all together and go with a single-instance, global rollout of SAP software using standard, out-of-the-box best practices to manage our business.
Consolidation and Scalability

In 1997, Universal Instruments completed its implementation, installing SAP software for enterprise resource planning (ERP), financials and controlling, inventory management, human resources, and other core aspects of the business. This gave us three things, says Jacobson. It gave us a single platform for the entire organization, consistent processes for managing our core business, and the ability to consolidate financially. Today, every nickel that flows through the company goes through our SAP software. This has helped us cut our monthly reporting time by more than half. And we can do amazing things with the numbers analyzing information across regions, customers, and product mixes. This just wasnt possible before at least not with any degree of efficiency.

The SAP implementation also gave the company the agility and responsiveness it required to succeed in the fast-paced, rapidly changing global market. The scale happened, as Jacobson puts it. Whenever its been necessary, weve been able to scale the business using standard SAP functionality.

Take, for example, the companys new plan to establish facilities in Brazil. Things have heated up there and we need a presence, says Jacobson. Itll take about 30 days to be up and running, but its no big deal for us now because our business processes are no longer an impediment.

Growing Fast While Reducing Cost

* Customer: Align Technology, Inc.
* Industry: Medical Device (Class II)
* Challenge: Implement a robust electronic document management system to support growth, as well as meet and maintain regulatory compliance.
* Solution: Arena
* Results: Align cut ongoing compliance cost by more than $250,000 annually. Change implementation used to take 22 days, but now takes only three to five days.
Align Technology, Inc. (NASDAQ: ALGN) is a medical device company engaged in the design, manufacture and marketing of Invisalign, the world's leading invisible orthodontic product. Invisalign is a series of clear, removable aligners that both orthodontists and general dentists use to straighten their patients' teeth. With more than twenty million unique aligners made to date, Align is one of the largest manufacturers of mass customized products in the world.

With operations in both Mexico and Costa Rica, Align's entire production process is documented in approximately 1000 highly detailed operating procedures and company SOPS, which must be accessed by more than 500 technical and production staff members. Additionally, another 400 employees from Align's development teams in Russia, and its corporate personnel worldwide, access the production information 24/7.
Challenge

In mid-2002, Align employed about 300 people. But with plans for major expansion, the company's management team identified electronic document management as a vital component for continued growth. The company then hired Meredith Yost, a 25-year industry veteran, to take charge of the document management initiative.

"Our executive team had the foresight to know that a scalable document control function is essential for growing the business," said Len Hedge, Vice President of Operations for Align in Santa Clara, Calif. "If you see implementation times for documentation changes increase, you may have already painted yourself into a corner, as Food and Drug Administration (FDA) regulations do not allow for shortcuts. We knew that investing in document management would be critical."

One of Align's business goals was to reduce the time needed to process change orders. Prior to implementing Arena, Align had managed change orders through manual, paper-based processes, which created a significant backlog and resulted in cycle times of sometimes up to 22 days. Additionally, management wanted to shift the change approval responsibility to the people involved in daily operations rather than relying as heavily on senior executives. Only then could the company increase internal efficiency and position itself for long-term growth.

Align managed production procedures and documentation in folders on a shared, read-only file server where only document control personnel could make modifications. Because all changes required manual updating on both the production folders and the "down-rev folders," personnel were required to duplicate work efforts to ensure referential integrity between documents.

Employees found it difficult to find the proper revisions of specific documents. Even with the "file search" capability, employees would turn up many versions of a documentonly one of which was the effective revision. The wasted time, when multiplied by the number of employees needed to find the effective document, and the number of times per day employees needed to access it, resulted in a high hidden cost.

The Invisalign system is designated as a Class II medical device, meaning that Align is required to follow the FDA's regulations on manufacturing and reporting. Align also distributes its product to Europe, requiring the company to adhere to ISO13485:2003 regulations. With the complexities associated with the FDA's Good Manufacturing Practice (GMP) and the European ISO standard, Align needed two full-time staff members in document control to manage compliance. Given the company's forecasted growth, executives expected Align would need a total of four full-time employees within two years.

It was abundantly clear to Yost that Align needed to migrate from its manual, paper-based documentation and change management processes to a comprehensive and automated document management system.

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It's about Process: Business Process Management Software

Companies are increasingly trying to adopt and implement standardized (and yet flexible and easily modifiable) business processes to help their operations run more consistently and smoothly. For example, the chief executive officer (CEO) might decide that as of, say, next month "All customer service cases must be resolved within 24 to 48 hours," or, "We are going to institute a new sales process for all deals worth over US$100,000."

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