Enhancing Plastic Processing Efficiency With ERP Solutions

CIO Applications Europe | Monday, August 14, 2023

Tailored ERP systems in the plastics processing sector offer intuitive integration, streamlined production modules, and optimised scheduling.

FREMONT, CA: The manufacturing sector possesses its distinct array of tools, processes, technologies, and challenges, which can frequently lead to heightened costs and additional tasks within processes. Therefore, it is imperative for business leaders to prioritise tailored solutions that cater to the unique needs and applications of enterprises, rather than relying on generic one-size-fits-all solutions.

A pertinent illustration of this lies within plastics processing, wherein industry leaders often utilize a generic enterprise resource planning program (ERP) to effectively amalgamate manufacturing and business processes. However, those at the forefront of the plastics sector must ensure that ERP systems are purposefully crafted to seamlessly integrate the entirety of the plastics business workflow. In addition to process improvements, this endeavour aims to achieve scalable bottom-line growth.

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An efficient enterprise resource planning system bestows amplified advantages upon plastics processors. These benefits encompass the optimisation of implementation timelines and operational costs within the domain, thereby guaranteeing a robust perspective and an intuitive interface for the ERP. In essence, standard ERP systems necessitate extensive customization and might result in extended deployment times and heightened costs. Conversely, embracing an ERP that incorporates plastics industry-specific manufacturing terminology and operational methodologies empowers an intuitive, swift, and dependable product configuration process.

An enterprise resource planning (ERP) module tailored for the plastics industry significantly enhances work efficiency within the domain while also effectively managing the workforce. This module incorporates embedded business rules and functionalities, resulting in intuitive systems that allow businesses to readily comprehend implications. Through its intelligent plastic-friendly approach, it not only saves time in plastic processing but also provides ongoing maintenance benefits. On the other hand, staffing a generic ERP project can introduce various challenges, whereas a plastics manufacturing ERP aims to reduce operational costs by 50 per cent in the upcoming periods.

For plastics processors to effectively harness the potential of ERP systems, a robust production module is paramount. Generic platforms often encounter implementation challenges that can lead to substantial expenses for customization, with limited additional functionality. This is precisely where ERP systems featuring a plastics production module come into play as a viable solution, offering straightforward and intuitive attributes. Plastics processing typically encompasses four distinct modules: injection, blow moulding, profile extrusion, and blown film or sheeting/thermoforming. Each module presents a complex environment requiring specialized software handling, potentially involving multi-layer recipes, co-extrusion, family moulds, alternate plastic recipes, regrind processes, raw material batches, inserts, and specialised tools like calibrators, line printing, and labelling. Therefore, plastic ERP vendors are now delivering versions that are appropriately customized to suit each process type.

These systems wield a significant influence in accurately calculating product costs and material requirements within plastics processes, extending to the scheduling of work orders while considering diverse constraints. The integration of a programmable logic controller (PLC) with a touch screen or label printer data acquisition station facilitates easy tracking of finished goods, lot numbers, and raw materials, and even facilitates the scaling of rejects for regrinding purposes and production advantages. Consequently, ERP-involved plastics processing is expected to undertake extensive trial runs, generating minor product samples from the initial scale to the finishing line, all of which involve operational costs.

Subsequently, an ERP-based solution tailored for the plastics processing industry must prioritise production scheduling and lead times. Plastic processors face a critical imperative to minimise operational downtime, emphasizing enhanced production efficiency and overall equipment effectiveness. Thus, an ERP-incorporated approach involves intelligent, interconnected planning that correlates with production effectiveness. It also encompasses quality and efficiency records across various machine options, all while considering material availability. Furthermore, this approach integrates alternative recipes with material requirement planning (MRP) and procurement strategies.

The optimisation of available production capacity plays a pivotal role in ensuring punctual deliveries within plastics processing. Simultaneously, it increases the volume of high-quality finished goods while minimising rejections. This optimisation extends to raw material utilization, culminating in improved overall operational profitability.

However, the complexity of production scheduling necessitates that business leaders adhere to specific guidelines to navigate the ever-evolving market landscape. This entails real-time identification of machine availability to optimize overall production runs. Equally, enterprise leaders must guarantee the prompt availability of machines, dies, moulds, and secondary equipment such as conveyors, grinders, calibrators, robots, and co-extruders. Vigilant tracking of maintenance schedules is also crucial.

Similarly, organisations within the plastics processing realm must ensure that MRP calculations dynamically transpire online, accommodating changes in work order placement within production runs. This facilitates immediate assessment of equipment and material availability for a given plastic recipe. In cases of unavailability, business leaders can readily opt for alternative recipes. Visualising all these aspects within an ERP system, utilising a drag-and-drop graphic scheduling tool, provides real-time visual alerts for impending deadline delays, material-related issues, and equipment conflicts.

The inclusion of production line operators in the printing package label process affirms the precise production of nearly X units. This confirms accurate resin lot number tracking and integrates quality control information onto the label. Furthermore, it encompasses critical production efficiency metrics, such as production speed and yields, in addition to valuable product and management insights. This integration eliminates front-office tasks.

Therefore, it is indisputable that the plastics processing industry necessitates specialised enterprise resource planning (ERP) solutions to effectively address its distinctive challenges and processes. Opting for tailored ERP systems designed for the plastics industry offers intuitive integration, streamlined production modules, and optimised scheduling. This results in improved efficiency, reduced costs, and heightened profitability. By embracing these solutions, business leaders can adeptly navigate the intricacies of plastics manufacturing, ensuring timely deliveries, superior products, and elevated operational performance.

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