Їe Pen Manufacturing Company was established during the mid-1990s and is located in Karnataka, India. Їe company is powered by its tip manufacturing facility and tool room, which has the capacity to design, develop and manufacture molds. Presently the company has the capacity to

1. Integrate Innovate Succeed
R
CASESTUDY
Inks the Best Solution
for the Digital Concerns of
Pen Manufacturing Companies
Roadmap ERP
www.roadmapit.com
No. 5, Republic Street | Reddiarpalayam |
Pondicherry - 605 010 | India
Phone: +91 413 4207 333
mktg@roadmapit.com
Roadmap IT Solutions (P) Ltd.
India | Middle East | Africa

2. Brief Company Pro le
e Pen Manufacturing Company was established during the mid-1990s and
is located in Karnataka, India. e company is powered by its tip
manufacturing facility and tool room, which has the capacity to design,
develop and manufacture molds. Presently the company has the capacity to
manufacture0.5millionmechanicalpencilsand1millionBallPensandisone
of the largest exporters of pens and mechanical pencils in India. e entire
productionofthecompanyisexported.
Brief Company Pro le
e Pen Manufacturer has a state of the art Tool room equipped with CNC machines, CNC Sparking machines;
super drilling machine and other machining facilities that provide high precision mold components for Injection
Pen/Mechanical Pencils Molds. e organization has around 80 injection molding machines and automated
assembly machines that are capable of producing over 50 million parts, which can be assembled to manufacture
millionsofBallpens,GelPensandMechanicalpencils.
e company follows Failure Mode and E ects Analysis (FMEA) process and Production Part Approval Process
(PPAP) to ascertain the manufacturing of good quality products. To enhance its Production mechanism and to
maintain high quality standards, the company has an online monitoring system, LAN with call escalation, built in
Visionsystem/PokeYokeininjectionmoldingandassemblymachines,FIFOsystemforWIPandFinishedGoods,
Preventive and Conditional based maintenance system, process control approach, and a well-equipped quality
testing Lab. To ensure employee safety and skills development, the organization adheres to environment and
personnelsafetystandardsandprovidestrainingandcontinuousimprovementprograms.
Reason to Choose Roadmap
e company had Excel and & Manual Registers to handle data transactions & reports, and there was no
codification for items. e Pen manufacturer has many products and di erent colors, so it could not
monitorthestocktransactioninthefollowingprocesses:
Inventory Control & Stock Transactions
Quality Control
System Generated Reports
Monitoring Stores Activities
Production Related Issues
Bill of materials for all products

3. Reason to Choose Roadmap
OtheraspectsthatcompelledtheorganizationtogoforanERPwere:
To avoid the existing Excel & Manual Data registers
To maintain the class & subclass
To systemize the existing oral communication in stores consumptions
To avoid the production of more items than in the orders
To generate systematic reports through ERP
To identify the estimated mold life in injection molding
To monitor machine idle times
To generate machine History
To rule out the pain points thus experienced, the company realized the need for an e ective ERP solution
and called for suitors. Of all the ERP solutions that responded to the Organization's call, it found Roadmap
ERP to be the technologically and economically best-fit system with the most amicable answers to address
eachoneofitspainpoints.
InventoryControl&StockTransactions
ePenManufacturermaintainedSKUs"StoreKeepingUnit"foritsFgs.
e company could not check the stocks at di erent stages of Production like injection molding item, printing
item,assembleditem&SKU(FG).
Inallprocess,theycouldnotchecktheQC&monitorthestockcolor-wise&product-wise.
Roadmap ERP captures Machine, Tool, Shifts, and Mold details, and enables the easy monitoring of
tool lifeandstock transactions atmultiplestages easily.
Roadmapcreateditem codi cationfor allitems and alsocategorized the items like RM,SFG, andFG.
e ERPprovidesthescopetocheckthe QCand tomonitorthestockcolor-wise&product-wise.
QualityControl
eCompanyusedmanualregister&manualreportforQualitycheckingprocess.
Roadmap con gured the inspection plans for Incoming QC, Line QC, Final
Inspection, and Pre-dispatch Inspection. Based on the plans the items and its
characteristics & speci cation are inspected and appropriates entries are made.
Oncetheentriesare done,thecorresponding report against theplan isgenerated.
The Pen Manufacturer's Pain Points Addressed by Roadmap ERP

4. MonitoringStoresActivities:
e Organization did not maintain Material Request/Material Issuance in the system, so there was a constant
mismatchintherawmaterials&consumablestransactions.
Based on the Production order, the Material Request and Material Issuance data are tracked by the Roadmap ERP
systemagainsteachandeveryProductionOrderandJobWork. isensuresthemaintenanceofStoresinaUniform
Structure,andespecially,byreducingtheunwantedCost.
SystemGeneratedReports
e Pen Manufacturer maintained only manual registers and reports and required systematic reports in all
areas.
In all the modules furnished by Roadmap, the ERP captures the existing reports format and provides system
generated reports for PO, Sales invoices, Packing List, Job Orders, Material Request Slip, Material Issuance Report,
StockReports,etc.
ProductionRelatedIssues
Productionusersproducedmoreitemscomparedtoorders.
Runner/Raiserwastageswerenotmonitored.
Moreconsumptionforproduction.
e ERP provides the scope to manufacture both on a make to
orderormaketostockmodes.
MRP1 - Material Requirement Planning -Based on the
Customer PO, the system runs MRP and releases the PO's and
JobOrders.
MRP2 - Material Resource Planning - Based on the MRP1, the
ERPrunstheResourceplanningincludingmanpower.
Other Process Entries - Based on the Production Order the
so ware schedules manpower and machine-power entries in
the ERP, and enables the tracking of each and every entry for a
SingleProductionOrder,sothattheProductionOrderforeach
andeverySalesOrdercanbetracked.
Production Order - e solution aids the input of Production
EntriesbasedontheSalesOrder,andensurestheeradicationof
unwanted Cost by facilitating the tracking of the cost of
ProductionEntriesagainsttheSalesOrder.
Roadmap ERP addressed all these issues and also helped better the existing system through the provision of the
following facilities:

5. Tool Life and Machine History - e Process monitors the entire history of the Machine and Tools and enables the
concerned stakeholders to clearly view the cost of operating the machinery and have a complete idea of
machine/toolidle/workingtimeagainsteveryProductionOrder.
Production Wastages - By finding the runners & raisers wastages against all injection molding transactions the
systemreduceswastagestoagreatlevel.
BillOfMaterialsforallproducts:
ecompanydidnothaveaBillofMaterialsforallproducts.
RoadmapERPcreatesBillofMaterialforallProductsandaccuratelydefinestheinputmaterialforeachproduction
order.
Roadmap ERP enables GST compliant inputs and outputs for Purchase, Sales and Finance oriented transactions of
thePenManufacturer.
Implementation Success
Roadmap, through its Business Process Re-engineering (BPR) approach, understood the needs
and purposes of the Concern's business processes. Roadmap's BPR experts effectively collaborated
with theOrganization's core-team and succeededinimplementing the ERP on-time.
e comprehensive integration of Roadmap full-suite ERP with the entire business process of the
Pen Manufacturing Company has eased its management by integrating all its functional units from
within and without. Roadmap ERP solution provides accurate details to precisely plan the
procurement and production processes. Further, it empowers the Stakeholders to make faster and
better management decisions by providing crucial information in a timely manner. e ERP has
ultimately delivered high ROI by totally solving all the snags that were pulling the company behind
from functioning smoothly.

6. e comprehensive integration of Roadmap full-suite ERP
with the entire business process of the Pen Manufacturing
Company has eased its management by integrating all its
functional units from within and without. Roadmap ERP
solution provides accurate details to precisely plan the
procurement and production processes. Further, it
empowers the Stakeholders to make faster and better
management decisions by providing crucial information in
a timely manner. e ERP has ultimately delivered high
ROI by totally solving all the snags that were pulling the
company behind from functioning smoothly.
No. 5, Republic Street | Reddiyarpalayam | Pondicherry - 605 010 | India
Phone: +91 413 420 7333
Email: mktg@roadmapit.com
Roadmap IT Solutions (P) Ltd.
Integrate Innovate Succeed
R
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