Falco SaaS for Manufacturing

Falco SaaS For OEMs

falco by Shantanu Joshi

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Falco MyKRA Business Intelligence Dashboards

Decintell Story By Shantanu by Shantanu Joshi

Decintell Falco Customer Experience Management (CEM) Module

Decintell Falco Knowledge Platform is a complete enterprise suite consisting an array of modules to cover enterprise wide transactions and workflows. The platform comes with its own Admin Centre. Admin can create roles, create users, assign roles and access rights. Configure alerts, emails etc. Admin can also monitor users' login sessions in real time and can force logout or suspend a user. Admin Centre is a very powerful tool to grant user level access to ensure information integrity. Apart from Admin Centre, Falco combines a set of standard modules and customised modules to handle complicated workflows within an Enterprise. (for more about Admin Centre click Decintell Falco Admin Centre) www.decintell.com

The standard modules are My KRA BI Dashboards, DOIT (IoT module to monitor equipment performance), WAC (weighment calibration app). The customized workflows are SWAS (an aftermarket suite), CPC (Constraint based Capacity Planning and Control), ECM (Engineering Change Management), CEM (Customer Experience Management), TPM (Total Preventive Maintenance), NPD (New Product Development) and many more. (for more on Decintell Falco Knowledge Platform click Digitise with Decintell Falco Knowledge Platform).

For the scope of this blog we will discuss CEM module in detail. "Customer Experience Management" is beyond standard CRM modules.

There are standalone off-the-shelf CRM platforms available. However, these platforms need to be adopted and even customised to suite specific workflow requirements of any organisation. Most of CRM platforms do not have proposal or quotation building engine. The complicated and costly licensing policies is another roadblock to adopt several of these platforms.

Decintell Falco CEM Module
CEM module goes way beyond just basic CRM solution. It is customised solution to fit your needs. CEM comes pre-loaded with value added features such as

Customer or Competitor Directory - Store address and contact information of the customer. Not just one location but any number of customer locations, their plants, offices, branches, warehouses. It is possible to flag the company as either Customer or Competitor or both.
People Directory - Register not only key people contact details, but also softer aspects about them, such as their role within the organisation, their relevance to your organisation i.e. influencer, user, decision maker, beneficiary, inclined towards competition, against, neutral etc. CEM has feature to track a person if he/she changes the role, location within customer organisation or joins another customer/competitor organisation. While generating a quote or proposal for any customer, these people specific attributes and their relevance to your organisation pops up and serves as guidance.
New Query Registration - Query registration from multiple sources such as website, exhibition stalls or your sales team. Query forms are designed to be internally allocated to different business verticals based on the query type. Each query form can be analysed for basic sanity, to decide if it is to be pursued or otherwise, saving huge time of generating proposals which end up nowhere.
Visit Reports - Register every customer visit and details of conversations. Generate and track action plan, assign actions to respective internal owners. If your organisation is already on Decintell Falco SWAS or DOIT modules, CEM allows seamless information feed from these modules. While preparing for visit it is easily possible to have complete overview of current status of customer complaints, spares orders as well as performance of your supplied equipment. This puts you at an advantage
Competitor Information - Log competitor information, including proposals submitted by them to customers, enabling “apples to apples” comparative analysis of commercial terms and technical specs offered by a competitor.
Market Intelligence - Log market information about your products, competitor products, photos, features, feedback received from customers. All this can be channelled into improving your product as well as new product development.

Decintell Falco CEM Module - Customised features
CEM has some unique customised features. Currently we have developed Proposal building for manufacturers and seller of equipment such as Lifts, Gen Sets, Industrial Compressors, or industrial machines.

Proposal Building and Vetting (escalation approvals) - Gather detailed user requirement (URS). Create huge Knowledge Repository of equipment features, accessories, site dependencies such as layout, power supply, compressed air circulation etc. URS is automatically validated against your equipment features, site conditions, other dependencies and correct equipment is selected. CEM also computes the price based on internal policies. If sales team wants to offer discounts, the proposal is automatically escalated for approval. And only approved quotation / proposal can be sent to customer. Thus every quote/proposal is vetted technically as well as commercially.
Handling Non-Standard URS - Many times customers ask for non-standard features in an equipment/machine. If the customer URS does not fit into standard equipment features, the query is automatically routed to engineering function to vet the URS. Engineering will study the same, decide if URS can be met with necessary modifications in the standard BOM. And if possible, what will be the cost of such modifications including lead time. Engineering then feeds necessary cost and lead time information in the query form. CEM calculates the price based on internal guidelines and from this point on the Non-Standard query flow follows the same workflow as a standard query. Since workflow for Non-Standard URS is separately handled, it doesn't hold processing of normal queries. This frees up engineering resources to focus on non-standard URS and conduct thorough vetting.
Quotation/Proposal Tracking - CEM tracks the proposal thru all stages till Win/Loss decision. Possible to generate multiple revisions of the proposal. Every revision is separately vetted and escalated, if necessary, for commercial approvals. The system decides if escalation is necessary.

CEM also hosts a Knowledge Repository (KRè). KRè stores data for equipment specifications, working conditions, accessories and thousands of combinations of interdependencies of all such variables. Ensuring URS is accurately vetted every time, without any manual dependencies. KRè allows hundreds of man years of experience and knowledge within your organisation to be centrally stored, drawn upon and effectively used, rather than this knowledge becoming proprietary to individuals. The knowledge gathered thru individual experience can be put to organizational benefit. KRè has controlled access and any change in data goes thru several steps of approval, before updating relevant masters.

CEM ensures seamless interconnectivity across various modules of Decintell Knowledge Platform, to bring data feed from SWAS, DOIT, WAC. True power of digitisation can be realised with Decintell Falco Knowledge Platform. CEM is currently under pilot testing. However, we appreciate that each organisation has its own specific needs and constraints. Leveraging our domain knowledge, we work closely with your team to map existing flow. Reengineer the same to remove non-value add activities. Optimize the flow to suite organisation specific requirements.

Decintell Falco Knowledge Platform helps your organisation to be a data driven, digitized enterprise.

Other relevant topics decintellfalco.blogspot.com

Shantanu Joshi
Co-Founder

Decintell Tech Pvt. Ltd.

www.decintell.com

Decintell Falco Total Preventive Maintenance (TPM) Module

The standard modules are My KRA BI Dashboards, DOIT (IoT module to monitor equipment performance), WAC (weighment calibration app). The customized workflows are SWAS (an aftermarket suite), CPC (Constraint based Capacity Planning and Control), ECM (Engineering Change Management), CEM (Customer Engagement Management), TPM (Total Preventive Maintenance), NPD (New Product Development) and many more. (for more on Decintell Falco Knowledge Platform click Digitise with Decintell Falco Knowledge Platform).

For the scope of this blog we will discuss TPM module in detail. TPM stands for Total Preventive Maintenance. Frequently TPM is also as defined as "Total Productive Maintenance" or "Total Predictive Maintenance".

Even at the cost of a little digression, I would like to discuss various definitions. Properly maintained machines and equipment does have high productivity, higher uptimes, higher quality reliability and of course longer machine working life. And collectively calling all these as "Productive" may be the intent behind using the term "Total Productive Maintenance".

Let us look at another definition of TPM. Total Predictive Maintenance. Can we really have "predictive" maintenance. For anything to be "predictive" one assumes that all potential failures of a machine, can be predicted. Yes, in theory it can be. But practically it is extremely difficult to achieve that, if not impossible. All the predictions are possible only thru past data. For any predictive pattern to be established, large amount historical data is needed and that too, accurately recorded. If an organisation starts building record for every machine thru regular preventive maintenance, breakdowns, spares changes, over years, then that can certainly be used by an artificial intelligence algorithm to come up with certain predictions. But therefore, calling it Predictive is going a bit overboard. I would suggest, not to get influenced with terms like Artificial Intelligence or Block Chain etc. As technologies, they may be advanced and effective, but the question is more about their actual utility in absence of consistent and large amount of data.

I am, therefore, personally more aligned with "Total Preventive Maintenance" as a definition of TPM. Total Prevention is a feasible target for an organisation. The intent of TPM is to ensure equipment health, so the breakdowns are minimized. And as a consequence, capacity calculations get more reliable. TPM has to be part of culture and has to be sustained constantly. TPM is not a one-time project, an activity for the month, or some yearly program. It is a culture. Many a times TPM initiatives fade out over a period because of lack of consistent monitoring.

Decintell Falco Knowledge Platform hosts a powerful TPM module.

TPM module enables the maintenance team

Draw maintenance schedule for every equipment for the entire year
Assign teams for the schedule
Keep team attendance and holiday calendar especially because they will have staggered weekly off schedule and will be entirely different from the rest of the personnel.
Centrally prepare checklists for every equipment along with part replacement plan
Plan spare parts
End to end breakdown ticket handling
Realtime feedback loop with Falco Capacity and Production Control (CPC)
Analytics

Other relevant topics. decintellfalco.blogspot.com

Shantanu Joshi
Co-Founder

Decintell Tech Pvt. Ltd.

www.decintell.com

Decintell Falco Admin Centre

The standard modules are My KRA BI Dashboards, DOIT (IoT module to monitor equipment performance), WAC (weighment calibration app). The customised workflows are SWAS (an aftermarket suite), CPC (Constraint based Capacity Planning and Control), ECM (Engineering Change Management), CEM (Customer Engagement Management), TPM (Total Preventive Maintenance), NPD (New Product Development) and many more. (for more on Decintell Falco Knowledge Platform click Digitise with Decintell Falco Knowledge Platform).

For the scope of this blog we will discuss Admin Centre. Admin Centre effectively controls every aspect of user interaction with Decintell Falco Knowledge Platform.

Role Management - The admin can create roles to suite your internal requirements and grant access to various modules. Access can also be controlled down to specific event within a module. Event such as Edit/Submit/Approve/Reject etc. can be assigned to specific roles. This will ensure integrity of data and workflow.

User Management - The admin can create new users and assign a specific role to a user. This enables a user thru the access rights assigned only to that specific role. Every new user goes thru approval process. User gets alert to sign-in, only post approval. Upon first sign-in user is required to change password for security reasons. User can start access based on the rights assigned to the role.

Alert Management - The admin can configure event specific alerts for every module. Alerts can be configured for specific users, the message body of an alert also can be configured. Alerts are sent via email.

Schedule Maintenance - The admin can schedule maintenance or updates and testing for Decintell Falco Knowledge Platform. While the updates are being configured, users will continue to get message on sign-in page and tentative time when it will resume.

Settings - The admin can set the start of financial year, holiday calendar, date format, currency settings as well as set number of days required to switch financial month after every month end. Every organisation may follow a different financial year calendar and the same can be easily configured. Decintell Falco Knowledge Platform is configured to handle month end and year end automatically.

Financial Period Switchover - Decintell Falco Knowledge Platform is configured to handle month end and year end automatically. At the end of every financial month, transaction posting of trial balances, cash flow, inventory, revenue etc. automatically switches over to next financial month. Whenever financial year ends all the financial and revenue budgets as well as actual postings are transferred to pervious years and next year budgets are transferred as current year to resume actual transaction posting. (for more about Budgets and Masters click Decintell Falco My KRA Dashboards )

Other relevant topics. decintellfalco.blogspot.com

Shantanu Joshi
Co-Founder

Decintell Tech Pvt. Ltd.

www.decintell.com

Decintell Falco Constraint based Capacity Planning & Control (CPC)

For the scope of this blog we will discuss CPC module in detail. CPC is a customized module to plan capacity loading, levelling the production load and tracking actual production against plan. It is designed to suite specific needs of an organisation. Many ERP systems normally assume infinite capacity model and therefore there is no visibility of available capacity.

Both, over and under capacity is highly risky. Definition of capacity includes installed capacity and manned capacity. In loose terms Installed capacity is the capacity of machines installed. And installed capacity can be productive only when it is adequately manned. Beyond these loose terms however, capacity is a very dynamic phenomenon, because of multitude of variables. The product mix, demand variations, equipment uptime, material availability, quality yield, absenteeism, to name a few.

Installed capacity is a sunk cost. It cannot be reduced. And addition to installed capacity has substantial cost and lead time. However manned capacity can be adjusted to cyclical variations in demand, with much lesser lead time. Even adding manpower can be a lengthy process due to learning curve of newly added headcount. And till the new hires achieve a certain degree of expertise, they tend to imbalance entire line.

Bottleneck neither is a fixed point, nor it is static. Bottleneck in a value stream is a completely dynamic phenomenon. For a given installed capacity, bottleneck keeps shifting due to multiple variables such as demand variation, product mix variation, manpower, equipment breakdown, input material quality. There are two types of bottlenecks. Short term and long term. Short term bottlenecks tend to be impacted more by near term reasons like, product mix variations, sudden demand fluctuations, equipment breakdowns, material shortages, poor quality of inputs. However, long term bottlenecks are governed by installed capacity, line balancing, pacemaker operation, process routing, product cycle time and two to five-year demand cycle.

Knowing the existing capacity or when and how to reduce or increase the capacity, is very critical to survival. It is like knowing where your off stump is. Capacity management is therefore a very complex subject, may be too complex to be handled manually. It is therefore highly desirable to digitise Capacity Planning.

Neither can one depend on standardised capacity planning, that is generally available as basic module in ERP systems. This workflow is a typical example of requiring a customised flow and therefore it is essential that this handled by domain experts.

At Decintell, we have deep domain knowledge to comprehend complexities of capacity planning and production tracking.

CPC brings instant visibility to existing as well as future capacity, based on the demand. If one were to load 12 months demand for viewing impact, CPC will show the stress areas and bottlenecks, both short and long term.

CPC considers all variables creating constraints on capacity, such as machine availability, manpower availability, material downtime, number of workdays, process routing, process cycle time.

Monthly demand, finished good stock and backlog is considered to arrive at net production load for the month. Net demand is uploaded to CPC Capacity module. Capacity module considers all near term constraints as explained above to arrive at loading. The capacity loading will show the under loading or overloading of various operations across all value streams. CPC Capacity module allows multiple iterations to arrive at best possible level loading of capacity to achieve max possible order fulfilment. Once the capacity loading is confirmed, CPC generates production tickets. Actual production can be filled against each operation. While production is in progress, Production Tickets allow change of route if there is any down time due to "man", "machine" or "material". Once the requisite production quantity is achieved production ticket can be closed. Production Tickets can be also short closed allowing back log to be transferred to next ticket or next production cycle.

CPC allows two methods of demand loading. "Regenerative" demand loading. New demand for monthly cycle is uploaded. Finished Goods stock is allocated against demand. This feature closes all open tickets. Transfers backlog to new demand.

New production tickets are generated. "Regenerative" run is normally taken once a month. The second method is "Net Change". Net Change method is used to accommodate small number of orders received during the month. Then instead running "Regenerative" cycle, it is better to run "Net Change". This method creates only net additional demand and generates additional tickets or adds to existing ticket, if same SKU ticket is already live. Existing production tickets are not affected.

CPC is a fully functional module of Decintell Falco. However, we appreciate that each organisation has its own specific needs and constraints. Leveraging our domain knowledge, we work closely with your team to map existing flow. Reengineer the same to remove non-value add activities. Optimise the flow to suite organisation specific requirements.

Decintell Falco Knowledge Platform helps your organisation to be a data driven, digitised enterprise.

Other relevant topics. decintellfalco.blogspot.com

Shantanu Joshi
Co-Founder

Decintell Tech Pvt. Ltd.

www.decintell.com