Departemen Teknik Industri FTI-ITB

TI-3122 Perencanaan dan Pengendalian Produksi Enterprise Resource Planning

Laboratorium Sistem Produksi www.lspitb.org 2003

Departemen Teknik Industri FTI-ITB

Pengertian ERP

Definisi dari ERP:

ERP covers the techniques and concepts employed for the integrated management of business as a whole, from the viewpoint of the effective use of management resources, to improve the efficiency of enterprise (Leon, 1999)

ERP Packages atau sering juga disebut sebagai enterprise system adalah perangkat lunak yang digunakan untuk mendukung implementasi ERP Merupakan perkembangan lanjut dari Manufacturing resource Planning (MRPII)

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Departemen Teknik Industri FTI-ITB

Pengertian..

Dengan ERP maka sebuah enterprise

memiliki metode dan teknologi untuk:

Mengotomasi dan mengintegrasi bagian utama dari bisnis

Sharing data dan praktek yang sama di seluruh perusahaan

Menghasilkan dan mengakses informasi dalam lingkungan yang real time.
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Departemen Teknik Industri FTI-ITB

Tujuan ERP

Enterprise Resource Planning

Process of using integrated application software to improve the effectiveness and efficiency of the entire enterprise

Purpose
Provide best practice functionality within departments and high level of integration across all enterprise functions

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Departemen Teknik Industri FTI-ITB

Tujuan ERP

ERP

Integrasi

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Departemen Teknik Industri FTI-ITB

Integrasi Informasi dengan ERP

Finance Strategic & Operational Planning

Human resource Manufacturing

ERP SYSTEM

Logistic management

Materials management Maintenance management Quality management Sales & Distribution

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Departemen Teknik Industri FTI-ITB

The Promise of Integration - SAP R/3 View of Manufacturing

Sales and Distribution
Sales planning Profit planning SOP Planned requirements Forecasts Customer order processing Shipping, billing, transport

Production Planning
Demand management Master planning Rough-cut capacity planning MRP/Planned orders Order - Creation - Release - Confirmation Shop floor control Capacity leveling Process planning

Materials Management
Direct requisition Purchasing Inventory management Goods receipt Material valuation Invoice verification Warehouse management

Quality Management
Lot inspection Process charting

Preventive Maintenance
Project system
Planned repair Emergency

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Departemen Teknik Industri FTI-ITB

Value Chain
profit margin
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Support Activity: infrastructure, hr, r&d, procurement Primary Activity:

inbound outbound marketing operations & sales service logistics logistics

Stream of activities.

Part of larger value system.

Applies to both products and services.
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Departemen Teknik Industri FTI-ITB

Obstacles to Integration
Change management Staff inadequacy Training Resource allocation

PEOPLE

PROCESS
Poor implementation management Inadequate reengineering Poorly planned transition

TECHNOLOGY

Inadequate functionality in integrating systems Weaknesses in application portfolio Weaknesses in data & reporting

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Departemen Teknik Industri FTI-ITB

Why ERP?

Reducing workforce in core transaction processing systems Supporting global business Achieving economies of scale Reducing information systems development staff

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Departemen Teknik Industri FTI-ITB

Why ERP? (contd)

Improving customer service Improving data integrity

Improving decision support

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Departemen Teknik Industri FTI-ITB

Costs and Benefits

ERP may cost several hundred thousand dollars for a mid-sized firm

Cost competitive among major vendors

Payback usually 6-30 months Savings based on 30% reduction in administrative and IS costs Consider operating costs

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Departemen Teknik Industri FTI-ITB

Software Komersial

Banyak tersedia software ERP komersial

antara lain:
SAP ORACLE BAAN J.D. Edwards, dll

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Departemen Teknik Industri FTI-ITB

Contoh: SAP

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Departemen Teknik Industri FTI-ITB

SAP R/3

Modular client-server architecture Sales and Distribution (SD) records sales orders and scheduled deliveries, information about the customer is maintained and accessed Materials Management (MM) manages the acquisition of raw materials from suppliers and the subsequent handling of raw materials inventory from storage to work-in-progress goods to finished-goods inventory Production Planning (PP) maintains production information production is planned, scheduled, and actual production activities are recorded Quality Management (QM) plans and records qualitycontrol activities like product inspection and material certification

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Departemen Teknik Industri FTI-ITB

SAP R/3

Plant Maintenance (PM) allows planning for preventive maintenance of plant machinery and managing maintenance resources Human Resources (HR) facilitates employee recruiting, hiring, training, payroll and benefits Financial Accounting (FI) records general ledger accounts transactions, generates financial statements for external reporting Controlling (CO) internal management manufacturing costs are assigned to products and cost centers to facilitate cost analysis

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Departemen Teknik Industri FTI-ITB

SAP R/3

Asset Management (AM) helps in managing fixed-asset purchases (plant and machinery) and related depreciation Project System (PS) planning and control of new R&D, construction, marketing as well as ERP projects Workflow (WF) automates activities in R/3 (e.g., prompts employees via e-mail if they need to take action) Industry Solution (IS) contains R/3 configuration settings for particular industries companies benefit from SAPs industry experience

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Departemen Teknik Industri FTI-ITB

Typical Basis Systems: Client Server Architecture

Presentation Application Database

Central System Two - tier Distributed System Two - tier Client/Server Three - tier Client/Server Multi-layer Cooperative Client/Server (w/ release 4.0B)
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Departemen Teknik Industri FTI-ITB

Implementasi ERP
1 2 3
Business Process MasterList
Project Plan Scope
Enhancements . Authorizations Reports Interfaces Processes Org. structure

System Performance

Baseline Scope

Procedures Test Cases

Reports Interfaces Conversion

Test Plan Train.Mat. Go Live Plan

Business Blueprint
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Departemen Teknik Industri FTI-ITB

Phase 1: Project Preparation

Explain roles and procedures. Prepare the Project Charter. Define schedule, budget, and resources. Provide initial training for project team.

Define technical requirements.

Prepare executive kickoff meeting.

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Departemen Teknik Industri FTI-ITB

Phase 2: Business Blueprint

Assess customer requirements through the interviews,
questionnaires, and models of the Business Blueprint.

Provide training for project team.

Install development system. Review the Business Blueprint

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Departemen Teknik Industri FTI-ITB

Phase 3: Realization

Customizing.
Customize the "Baseline" system, which covers 100 % of the organizational structure and 60% of all daily business operations. Check that this Customizing realizes your business processes (first integration test).

Final Integration Test.

Check other business processes which may be indirectly affected. Design, develop, and test interfaces, reports, and data conversions.

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Departemen Teknik Industri FTI-ITB

Phase 4: Final Preparation

Planning for going live data.

Training end users.

Testing: integration, volume, and stress. Establishing an internal Help Desk. Cutover to production environment.
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Departemen Teknik Industri FTI-ITB

Phase 5: Go Live and Support

Start of production operation.
Setting up support. Verifying the accuracy of the production system. Measuring business benefits. Optimizing performance.
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Departemen Teknik Industri FTI-ITB

Critical Success Factors of ERP

Strong top management support Centralized project management Strong IT management and staff support Heavy user involvement Business process reengineering to
standardize on software capabilities

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Departemen Teknik Industri FTI-ITB

Critical Success Factors of ERP

Retraining of existing software developers in ERP Extensive training of end users Use of consultants to lead implementation and training

A respected and effective champion of ERP within

the organization

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Departemen Teknik Industri FTI-ITB

Critical Success Factors of ERP

Effective and continuous communication Top-notch systems analysts Retaining analyst throughout project and beyond

Sensitivity to user resistance with new systems

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Departemen Teknik Industri FTI-ITB

Success Stories
Autodesk (computer aided design software maker) IBM Storage Systems Division
Reduced delivery time from two weeks to less than 24 hours Reduced time to re-price 5 days to 5 minutes Time to ship a replacement part 22 to 3 days Time to complete a credit check 20 minutes to 3 seconds

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Departemen Teknik Industri FTI-ITB

Success Stories

Fujitsu Microelectronics
Reduced the cycle time for filling orders from 18 days to 1.5 days Time to close financial books from 8 to 4 days

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Departemen Teknik Industri FTI-ITB

Horror Stories
FoxMeyer Drug software helped drive the company into
bankruptcy Dell computer software will not fit its decentralized management model Applied Materials overwhelmed by the organizational changes involved Dow Chemicals spent seven years and 500 million dollars on R/2 now starting again with R/3 Hersheys missed timely deliveries

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Departemen Teknik Industri FTI-ITB

Reasons for failure

Software logic and the company strategy may not match!

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Departemen Teknik Industri FTI-ITB

Conclusions

ERP has great potentials for integrating organizational information systems Also has great risks Enterprise systems need to be implemented after careful thought and as a part of a firms overall strategy

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