Inventory Programming

Cost estimation software for product developers and manufacturing engineers with links to the manufacturing database

Software was developed using DBASE IV to enable design and manufacturing engineers to estimate product cost - materials, direct labor, variable overhead, and fixed overhead. Libraries of standard material costs were created, and calculations made based on dimensional descriptions of parts and part geometry. In addition, tables of standard time (for setup and runtime) were created to ease the allocation of labor costs. These standard times were based on various factors such as part size, #of operators, # of hits (in a press) etc. The program prompted for standard workcenters such as Shear, Punch, CNC punch, Brake etc. It also allowed for the creation of non-standard work centers. The process data can then be transferred to an existing MRP database using an ASCII link - this eliminates double data entry into two separate data bases.

Results:

Accurate cost estimates that allow product development, product design and manufacturing departments of an engineering department to communicate with one voice to management. Improved productivity within the engineering department. Detailed cost reports as well as cost summaries can be generated in minutes as opposed to days. This software is currently being converted to a Microsoft Access based system.

Work & Cost Estimation

Costing program for a Steel coating company

A custom designed software is being developed for a company in the business of coating Steel. This software is being developed in Microsoft Access to address the costs of coating Steel across two distinct production lines. In addition to improving the productivity of the person quoting the "jobs", the software will ensure that manufacturing costs including labor related to processes and material handling are being accurately captured.

Results:

Improved productivity in the process of providing quotes, and improved accuracy of quotes provided.

Engineering Support/Design

Development of a database for custom engineered shower enclosures

CASI engineers have developed database which assists engineers in calculating and generating a custom Bill of Materials for various designs of shower enclosures. The software calculates the cut to length dimensions of the extrusions that make up the frame of the enclosures for square as well as out-of square openings. The shower enclosures vary from door only enclosures to door & panel as well as multi-plane enclosures. The glass dimensions are also calculated by the software. The software has been developed using Microsoft Access and Visual Basic.

Results:

Improved productivity (the time to prepare a Bill of Materials is reduced from several hours to less than 10 minutes), and improved accuracy (because the calculations to develop the Bills of Materials can be quite tedious, the process is error prone - the database/automated approach minimizes mistakes).

Manufacturing Requirement Programming

Distributed MRP software development.

A Microsoft Access based program (including programs developed in Visual Basic) was developed to allow a manufacturer of large trucks to create Item Masters and Bills of Materials for truck parts and assemblies, and issue manufacturing orders against these. When an order is issued against an assembly, the software explodes through the Bills of Materials and issues orders for all the parts required. The software also allows the user to track the orders as they move through the shop floor by letting the various departments (such as fabrication, welding, assembly etc.) access the system, and check and modify the orders processed in their departments.

Results:

Work order generation and tracking for multi-level Bills of Materials has migrated from a manual system to a fully automated system. Shop floor tracking (of Work Orders) for a factory spread out over 200,000 square feet and seven buildings is now being automated. Both these facts represent a tremendous boost in productivity for the organization.

Sales Support and Customer Service

Sales Tracking Software Application

A Microsoft Access based software application was developed for a major manufacturer of hydraulic seals which allows sales engineers to create an applications database identifying potential markets for their products. Applications engineers at the factory in turn update this database when they identify solutions to the potential seal applications. The software makes use of OLE and DDE to capture customer data from a contact management software which is used by sales engineers at Greene Tweed. This link between the applications software and ACT (the contact management software used) results in customer information being created only once, and eliminates duplication of customer information. Various sorting features are provided in the software solution which allows engineers to identify similar seal applications, track and prioritize applications by sales dollar potential etc.

Results:

The method by which potential applications are identified and tracked has been standardized as a result of this software. Green Tweed engineers can use the sorting features provided to quickly identify existing solutions to new applications which have been identified by the sales force.

Labor Tracking Programming

Labor Tracking Software Application

Data entry for employee labor info. The Labor Tracking Program kept track of Labor related information for each shift, employee and day.

Results:

The program allow the customer the track labor and report labor information for specifice dates.

Business system for quotation and order tracking

This software is being developed for a client who is in a repair business which is closely tied with the automobile industry. The software is being developed in Microsoft Access for the purposes of estimating repair cost, providing quotations to customers, and tracking orders on the shop floor. This software ties in with an accounting package that we are helping to implement. The pricing module being developed for the customer is designed to handle non-linear pricing requirements.

Results:

Productivity in the front office is expected to increase dramatically. In addition, several management reports that were impossible to obtain using the manual system are being used. These management reports are to be used to help improve marketing efforts among other planned improvements.

Database conversion and software support.

Proposed, designed and implemented a system of programs to modify a large number of programs supporting Sales Administration, enabling them to use a copy library. Coded programs to convert data in existing database to data in new database design implemented in support of sales administration. Designed and implemented county wise business patterns database with its user interface for the Marketing Department. Provided software support related to Engineering, Manufacturing, and Payroll departments in terms of developing new code and helping to maintain/enhance existing code.

Results:

On-site support resulted in faster and better use of available information in the MIS department.

Software support related to merger of two companies

A CASI software engineer coordinated activities of a team of seven programmers in the conversion of the billing system and introduced documentation standards for the project. The new billing system was successfully implemented and operational within the stipulated time. Provided software support by developing new code and enhancing existing code related to Tax and Budget Planning departments.

Results:

The Tax and Budget planning departments were able to support the merger created requirements for consolidating the activities in the Billing, Tax & Budget Planning Departments.

Sales Applications tracking software

A Microsoft Access based software application was developed for a major manufacturer of hydraulic seals which allows sales engineers to create an applications database identifying potential markets for their products. Applications engineers at the factory in turn update this database when they identify solutions to the potential seal applications. The software makes use of OLE and DDE to capture customer data from a contact management software which is used by sales engineers at Greene Tweed. This link between the applications software and ACT (the contact management software used) results in customer information being created only once, and eliminates duplication of customer information. Various sorting features are provided in the software solution which allows engineers to identify similar seal applications, track and prioritize applications by sales dollar potential etc.

Results:

The method by which potential applications are identified and tracked has been standardized as a result of this software. The Engineers can use the sorting features provided to quickly identify existing solutions to new applications which have been identified by the sales force.

Expert System

Expert system for manufacture of electrodes for an EDM machine

A computer based expert system was developed to aid in the manufacturing of electrodes for an Electrical Discharge Machine (EDM) tool. These electrodes are used in the manufacture of mold blocks for injection molded plastic molds. To create the expert system, this project traced the flow of information and materials within the company, determined where key decisions effecting the electrode's manufacture are made, and interviewed many experts to find out how these decisions are made. The results of these interviews were used to create an expert system.

Results:

Key information about the EDM process was provided to engineers which allowed them to not only design a part, but also the means of manufacturing a part. This in turn reduced the time required to manufacture molds.