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MANATEC ELECTRONICS PRIVATE LIMITED
‘RoadmapERPfacilitated'ManatecElectronics'byitsagile
&innovativeintegrationprocess’
ROADMAP ERPSUCCESS STORY
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MANATEC ELECTRONICS PRIVATE LIMITEDPONDICHERRY
AboutCompany
MANATEC is one ofAsia's largestOEMof automotive garage equipments. Located in Pondicherry, India, the
companymanufacturesWheelAligners,WheelBalancers,TwoPostLifts,Gasanalyzers,SmokeMeters,Headlamp
aligners&DigitalAirTirein�lators.
Established in the year 1987, as amanufacturer of industrial shaft aligners,Manatec diversi�ied into garage
equipment industry in 1991. The company, through its in-houseR&D, indigenously designed anddeveloped
Opticalwheelalignmentsystemsin1991,tobecomethe�irstcompanytodesignawheelalignerinthewholeof
Asia.
Manatec'sextensiveWheelAlignerinstallationsacrosstheworldspeakforitsquality,specializationandlead
roleweplayinthisindustry.
Wheel Aligners
Wheel Balancers
Two Post Lifts
Gas analyzers
Smoke Meters
Head lamp aligners
Digital Air Tire inflators.
NO.OFEMPLOYEES 200+ 2PONDICHERRY,INDIALOCATION PRODUCTSNO.OFUNITS
PAGE 01
“Roadmap team has done an excellent job in
meeting the extremely aggressive time-line for our
Business; we are highly pleased with their
performance and realize that, they have worked
roundtheclock,tomakethishappenforus.
We are very impressed with the ability to
deliverwhatwas promised, on budget,
andaheadofschedule."
ROADMAP ERPIntegrate Innovate Succeed
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PAGE 02SUCCESS STORY
ERP Selection ProcessIn 2006, MANATEC was looking for highly scalable, robust, cost effective ERP
solutions to meet its growing business needs. After evaluating several ERPs,
MANATEChaschosenRoadmapERPwhichhasmetallitsevaluationcriteria.
CoreobjectiveforimplementingERPisto,
Ÿ Integratebusinessprocesses
Ÿ Eliminateredundantdataentry
Ÿ Enable consistent planning of material, resources in production, sales, and
procurement
Ÿ Have effective control over every step of the operation, from purchase to
productionto�inaldelivery
Ÿ EliminatethetimespentbyeverydepartmentresourceforpreparingMIS
reportsinExcelsheetsandPowerPointpresentation
MANATEC used 4 d ifferent
Softwareapplications,tohandle
Finance,SupplyChain,Planning
& Manufacturing, CRM and HR
Functions and encountered the
followingobstacles.
NoIntegrationRedundantDataEntryReconciliation of data betweenmodu les was cumbersomeprocessManual preparation of MISreports which lead to mistakesandtimeconsumingNoeffectivecontrolLackofsearch-abilityLimitedfunctionalityInability to provide accuraterecords
Roadmap ERPwas planned to implement in 4Months period;
wherein,Roadmaphasinvolveditsseniormanagementtomake
theprojectsuccessful.Toachievethesuccessfulimplementation,
Roadmap Team has put enormous effort in all phases of
Implementationi.e.AS-IS,Gap-Fit,TO-BE,Design,Customization,
TrainingtheUsersetc.
Manatec follows 'Make-To-Stock' strategy. It prepares sales
forecast for the �inished goods and spares based onmarketing
teaminput;thereon,plansandpurchasestherequiredmaterials.
Production department produces the subassemblies, and
assemblesthe�inalproductthroughitsshop�looroperationsand
subcontractorprocesses.
Each Product Group contains multiple models and every
equipmentconsistsof1500to2000componentswhichneedtobe
accuratelyplanned,purchased,manufactured toassemble the
�inalproduct;andinwhich,30to40%ofthecomponentswere
interchangeable.
Requiredcustomizationsweredeveloped,tested&implemented
andTrainingprocessarecarriedouttoallmoduleusers;wherein,
thefeedbackwascollectedandaddressedontimelymanner.
IMPLEMENTATION
DIFFICULTIESDIFFICULTIES
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PAGE 03SUCCESS STORY
ROADMAP ERP
MODULES IMPLEMENTED
Financial Management
General Ledger Management
Accounts Payables Management
Accounts Receivables Management
Cash Management
Fixed Assets
Cost Management
Taxation
Sales & Distribution
Purchase Order Management
Subcontract Order Management
Quality Management
Inventory Control Management
Sales Order Management
Customer Relationship Management
Marketing
Customer Support
Planning & Manufacturing
Bill Of Material
Sales Forecast
Demand Management
Master Production Schedule
Material Requirement Planning
Shop Floor Management
Manufacturing Scheduling
HR / Payroll
Portfolio Management
Leave Management
Loan Management
Performance Appraisal
Payroll
Engineering
Implementation Challenges Codi�ication:SeparateItemCodehadbeenmaintainedfor
eachprocessinRouting.Classifyingandconvertingthemas
FGandSubAssemblyItemsand�ixingproductroutingtook
lotsofeffortandtime.
DataMigration:Anotherchallengewastomigratethedata
fromlegacysystemtoRoadmapERPSystem;inwhich,data
migrationofmastersandcut-offdatarequiredhugevolume
ofdatacleaning,andvalidation.
ShopFloorstagewisecompletionsneedtobetrainedtoShop
FloorUsersandtheywereverynewtoERPSystem.
Thousands of Materials need to be carefully planned and
procured.
Rawmaterials,BoughtOut,WorkInProgress,FinishedGoods
stocksrequiredtobeclassi�iedproperlyandmigrated.
S-ISA
GAP FIT A
NA
LYSIS
CN USOI TT OAZI M
ROADMAPERP
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PAGE 04SUCCESS STORY
ROADMAP ERP
IMPLEMENTATION HIGHLIGHTS
BENEFITSBENEFITS
Successful MRP: Foremost objective is to make MRP successful for vast spread
operations.Roadmaphadmadeitssuccessinshortestdurationandthereby,visualized
lotsofmateriallyinginWIP;witheffectiveInventorysystem.ProperInventoryenabled
tohavecompletevisibilityinmaterialstock,Planningandsubsequentprocurements.
Obsolete and Non–Moving Materials: Obsolete and non-moving materials were
identi�iedandcorrectiveactionsweretaken.
Trackingof sub-contractors stockofmaterial:Roadmap integration hadmade
successful tracking stock at Sub-Contractors; System enabled subcontracting
departmenttohavephysicalcountofsubcontractor'sstockandcompare&takethe
correctiveactionsforthedeviations.
DefectivesparesatServiceCenters,Fieldengineerswereindenti�iedandtakenfor
�ixingthesparesandmovedbacktotheSparesInventory.
ManagingMarketingActivities:ByRoadmap,Marketing&PromotionalActivities
werecarriedintimeandtheprocessofenquiry,customerrelationship,quotationsand
delivery weremade easier. System accuracy enabled insight view of the activities
prevailinginthemarketwhichenhancedtotakeprudentdecisionsintime.
Follow-up of Equipments AMC: Systemmade possible to provide triggers for all
pending,expiredandduesinrelatetoAMCSupport.Instantgenerationofinvoiceswas
madeeasierandlesstimeconsuming;througheffectiveviewofcustomerrecords.
Roadmap System gone Live within 4 Months of time by implementing & integrating all core modules; in which, submitting project plan, simultaneous support with existing operations, importance to customization & System Live were all done within the scheduled period of 4 months.
MANATEC has given excellent cooperation in all phases of project Implementation Process. Project review meetings, workshops were conducted time to time; wherein, all feedbacks, requirements received from module Users were considered and addressed on time.
Training process were organized to explain the functionality and thereby ensured operational excellence at user levels.
By means of having timely cooperation from MANATEC, the project was able to accomplish within the stipulated time frame.
SCALABLE
EFFICIENCY
CONTROL
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PAGE 05SUCCESS STORY
ROADMAP ERP
Support toTradingActivities:TomanageTrading businessmore effectively and
ef�iciently, Roadmap had proposed a best �it suite to address areas such as Sales
management, Customer Relationship management, Easy purchases, warehouse
handlingandstock&inventorymanagementetc.
Time-consumingeffort to �indchangehistories:Foundhard toaccomplish jobs
whichneedstobeaddressedintimeandofaccuracyinoperations.Roadmapenabled
thesystemtogetintothestrategicstandardsintimeandhelpedtotakemanagerial
decisionatrighttime.
BetterVisibility&Control:Bettervisibilityintoproduction&warehouseoperations,
inventorylevels,stagewisestockinshop�loorandwithsubcontractors/suppliers.
ReducedDataEntryProcess:Automatedprocesseliminatedredundantdatare-entry
whichsavedlotsoftimeandenergyatdifferentlocations
Work�lowbasedapprovals:Properwork�lowbasedapprovalsensuredrightperson
authenticatingthedocument.
ImprovedPlanning:Completeassistanceforcomplexplanningandtherebyenriches
forecastingcapabilities.
Traceabilityofrejections:Ateverystageofinspectionprocessi.e.MaterialInward,
ShopFlooretc.therejectionswereidenti�iedandprecautionarystepsweretakenfor
betterusageofMaterial.
SubcontractorsProcesshandlingmadeeasier:Systemmadeeasytosendmaterial
to subcontractors for single ormultiple processes and enabled to receive partially
processed,fullyprocessedandunprocessedmaterialsandadjustthedeliveryChallan
quantityaccordingly.
Post Sales Service: Establishment of online service capability forwarrantymade
mucheasierwithenormouscustomreportsintime.Providesbettercustomerservice
throughimprovedinventorycontrolandstockholdings
Improved Customer Satisfaction: Through easy contact management, customer
satisfactionisensured.
TimelyReportingStructures:Better,fasterdecisionmakingwithtimelyreporting
structuresavailableinsourcemadereportingeasier.
UpgradedSysteminplace:Supportsforlong-termgrowthbyinnovativeand
upgradedsystem.ERPprovidesastate-of-the-artintegratedmodulesetdelivering
strongaccountingand�lexiblemanufacturingfunctionality.
BENEFITSBENEFITS
No. 5, Republic Street | Reddiyarpalayam | Pondicherry - 605 010 | India Phone: +91 413 420 7333Email: [email protected]
www.roadmapit.com
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RoadmapITSolutions(P)Ltd.
SUCCESS STORY
CorporateOperationalOf�ice:No.4,Akshaya,IstFrontBlock,VysyaBankColony,SarakkiMain,JPNagar1stPhase,NearRajlakshmiHospital,Bangalore-560078.Ph:9663308001
RegionalOf�ice-Chennai:No.11,FirstFloor,SamiyarGardenStreet,AshokNagar,Chennai-600083.Ph:+919442510123
RegionalOf�ice-Coimbatore: Old.No.20,NewNo.39,VinayagarKoilStreet,1stFloor,KrishnasamyNagar,Coimbatore-640045,India.Ph:+919442580742
RegionalOf�ice-Mumbai:AnmolPlanetBldg.,Of�iceNo.5,Plot.211,Kopra,Kharghar,NaviMumbai-410210,India.Ph:+919930305054
RegionalOf�ice-Baroda:ShopNo:23,UpperGroundFloor,SilverRockComplex,Bhavan'sSchoolCircle,Vadodara-390004,Gujarat,India.Ph:+917698695109
OverseasOf�iceMiddleEast:ZaitunahCommercialCenter,Of�iceSuit#205;BldNo.7097,Jeddah-23343-3523,KSA.Tele/Fax:+96612613381
Europe:FidelitasSA,15,ruedeCendrier,1201Geneve,Switzerland.Ph:+41793755566.
Africa:7TroonCresent,SilverLakeGolfEstate,Pretoria,SouthAfrica.Ph:+27610807322.
SriLanka(PartnerOf�ice):ProvidenceGlobal(Pvt)Ltd,752/1Dr.DanisterdeSilvaMawatha,Colombo09,SriLanka.Ph:+94768373971