Published on February 27, 2014
Welingkar’s Distance Learning Division ERP & WEB BASED SUPPLY CHAIN MANAGEMENT Chapter 2 ERP Strengths & Weaknesses Chapter2 1
Welingkar’s Distance Learning Division ERP Strengths & Weaknesses ERP Investment ERP has become the buzz word all over the word. Is ERP really justified considering prohibitive high cost? This chapter analyses the Strengths & Weaknesses of the ERP. ERP software costs in Crores, besides there is cost of Implementation of ERP. An organization has to pay the consultancy fees to outside consultant. besides there is cost of training the manpower. These costs are trice the cost of software. Chapter2 2
Welingkar’s Distance Learning Division ERP Strengths & Weaknesses There aren’t any good numbers to predict ERP costs because the software installation has so many variables, such as: the number of divisions it will serve, the number of modules installed, the amount of integration that will be required with existing systems, the readiness of the company to change and the ambition of the project—if the project is truly meant to be a battering ram for reengineering how the company does its most important work, the project will cost much more and take much longer than one in which ERP is simply replacing an old transaction system. There is a sketchy rule of thumb that experts have used for years to predict ERP installation costs, which is that the installation will cost about six times as much as the software license. Chapter2 3
Welingkar’s Distance Learning Division Hidden costs of ERP There are some costs which are underestimated or overlooked When ERP is implemented. The following areas merit our attention. 1. Training—Training is the near-unanimous choice of experienced ERP implementers as the most underestimated budget item. Training expenses are high because workers almost invariably have to learn a new set of processes, not just a new software interface. Worse, outside training companies may not be able to help you. They are focused on telling people how to use software, not on educating people about the particular ways you do business. Chapter2 4
Welingkar’s Distance Learning Division Hidden costs of ERP Prepare to develop a curriculum yourself that identifies and explains the different business processes that will be affected by the ERP system. One enterprising CIO hired staff from a local business school to help him develop and teach the ERP business-training course to employees. Remember that with ERP, finance people will be using the same software as warehouse people and they will both be entering information that affects the other. To do this accurately, they have to have a much broader understanding of how others in the company do their jobs than they did before ERP came along. Ultimately, it will be up to your IT and businesspeople to provide that training. Chapter2 5
Welingkar’s Distance Learning Division Hidden costs of ERP Integration and testing Testing the links between ERP packages and other corporate software links that have to be built on a case-by-case basis is another often-underestimated cost. A typical manufacturing company may have add-on applications from the major—ecommerce and supply chain—to the minor—sales tax computation and bar coding. All require integration links to ERP. You’re better off if you can buy add-on s from the ERP vendors that are pre-integrated. If you need to build the links yourself, expect things to get ugly. As with training, testing ERP integration has to be done from a processoriented perspective. Chapter2 6
Welingkar’s Distance Learning Division Hidden costs of ERP Customization Add-ons are only the beginning of the integration costs of ERP. Much more costly, and something to be avoided if at all possible, is actual customization of the core ERP software itself. This happens when the ERP software can’t handle one of your business processes and you decide to mess with the software to make it do what you want. You’re playing with fire. The customizations can affect every module of the ERP system because they are all so tightly linked together. Upgrading the ERP package—no walk in the park under the best of circumstances— becomes a nightmare because you’ll have to do the customization all over again in the new version. Chapter2 7
Welingkar’s Distance Learning Division Hidden costs of ERP Data conversion It costs money to move corporate information, such as customer and supplier records, product design data and the like, from old systems to new ERP homes. Although few CIOs will admit it, most data in most legacy systems is of little use. Companies often deny their data is dirty until they actually have to move it to the new client/server setups that popular ERP packages require. Consequently, those companies are more likely to underestimate the cost of the move. But even clean data may demand some overhaul to match process modifications necessitated—or inspired— by the ERP implementation. Chapter2 8
Welingkar’s Distance Learning Division Hidden costs of ERP Data analysis Often, the data from the ERP system must be combined with data from external systems for analysis purposes. Users with heavy analysis needs should include the cost of a data warehouse in the ERP budget—and they should expect to do quite a bit of work to make it run smoothly Consultants ad infinitum When users fail to plan for disengagement, consulting fees run wild. To avoid this, companies should identify objectives for which its consulting partners must aim when training internal staff. Include metrics in the consultants’ contract. Chapter2 9
Welingkar’s Distance Learning Division Hidden costs of ERP Replacing your best and brightest It is accepted wisdom that ERP success depends on staffing the project with the best and brightest from the business and IS divisions. The software is too complex and the business changes too dramatic to trust the project to just anyone. The bad news is a company must be prepared to replace many of those people when the project is over. Implementation teams can never stop Most companies intend to treat their ERP implementation as they would any other software project. Once the software is installed, they figure the team will be scuttled, and everyone will go back to his or her day job. Chapter2 10
Welingkar’s Distance Learning Division Hidden costs of ERP But after ERP, you can’t go home again. The implementers are too valuable. Because the implementers have worked so closely with ERP, they know more about the sales process than the sales people and more about the manufacturing process than the manufacturing people. 9) Waiting for ROI One of the most misleading legacies of traditional software project management is that the company expects to gain value from the application as soon as it is installed, while the project team expects a break and maybe a pat on the back. Neither expectation applies to ERP. Chapter2 11
Welingkar’s Distance Learning Division Hidden costs of ERP Most of the systems don’t reveal their value until after companies have had them running for some time and can concentrate on making improvements in the business processes that are affected by the system. And the project team is not going to be rewarded until their efforts pay off. 10) Post-ERP depression The most common reason for the performance problems is that everything looks and works differently from the way it did before. When people can’t do their jobs in the familiar way and haven’t yet mastered the new way, they panic, and the business goes into spasms. Chapter2 12
Welingkar’s Distance Learning Division Benefits of ERP 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Reduction in inventory Redeployment of personnel Productivity improvement Order management cycle improvement Financial close/cycle reduction IT cost reduction Procurement cost reduction Cash management Improvement Transportation cost reduction Hardware maintenance reduction Software maintenance reduction On line delivery improvement Chapter2 13
Welingkar’s Distance Learning Division Advantages Design Engineering (how best to make the product) Order tracking from acceptance through fulfillment The revenue cycle from invoice through cash receipt Managing interdependencies of complex Bill of Materials Tracking the 3-way match between Purchase orders (what was ordered), Inventory receipts (what arrived), and Costing (what the vendor invoiced) The Accounting for all of these tasks, tracking the Revenue, Cost and Profit on a granular level. Chapter2 14
Welingkar’s Distance Learning Division Five Major Reasons for understanding ERP 1) Integrate financial information As the CEO tries to understand the company’s overall performance, he may find many different versions of the truth. Finance has its own set of revenue numbers, sales has another version, and the different business units may each have their own version of how much they contributed to revenue. ERP creates a single version of the truth that cannot be questioned because everyone is using the same system. Chapter2 15
Welingkar’s Distance Learning Division Five Major Reasons for understanding ERP 2) Integrate customer order information ERP systems can become the place where the customer order lives from the time a customer service representative receives it until the loading dock ships the merchandise and finance sends an invoice. By having this information in one software system, rather than scattered among many different systems that can’t communicate with one another, companies can keep track of orders more easily, and coordinate manufacturing, inventory and shipping among many different locations simultaneously. Chapter2 16
Welingkar’s Distance Learning Division Five Major Reasons for understanding ERP 3) Standardize and speed up manufacturing processes Manufacturing companies—especially those with an appetite for mergers and acquisitions—often find that multiple business units across the company make the same widget using different methods and computer systems. ERP systems come with standard methods for automating some of the steps of a manufacturing process. Standardizing those processes and using a single, integrated computer system can save time, increase productivity and reduce headcount. Chapter2 17
Welingkar’s Distance Learning Division Five Major Reasons for understanding ERP 4) Reduce inventory ERP helps the manufacturing process flow more smoothly, and it improves visibility of the order fulfillment process inside the company. That can lead to reduced inventories of the materials used to make products (work-in-progress inventory), and it can help users better plan deliveries to customers, reducing the finished good inventory at the warehouses and shipping docks. To really improve the flow of your supply chain, you need supply chain software, but ERP helps too. Chapter2 18
Welingkar’s Distance Learning Division Five Major Reasons for understanding ERP Standardize HR information—Especially in companies with multiple business units, HR may not have a unified, simple method for tracking employees’ time and communicating with them about benefits and services. ERP can fix that. Chapter2 19
Welingkar’s Distance Learning Division Five Major Reasons for understanding ERP In the race to fix these problems, companies often lose sight of the fact that ERP packages are nothing more than generic representations of the ways a typical company does business. While most packages are exhaustively comprehensive, each industry has quirks that make it unique. Most ERP systems were designed to be used by discrete manufacturing companies (that make physical things that can be counted), which immediately left all the process manufacturers (oil, chemical and utility companies that measure their products by flow rather than individual units) out in the cold. Each of these industries has struggled with the different ERP vendors to modify core ERP programs to their needs. Chapter2 20
Welingkar’s Distance Learning Division Disadvantages Success depends on the skill and experience of the workforce, including training about how to make the system work correctly. Many companies cut costs by cutting training budgets. Privately owned small enterprises are often undercapitalized, meaning their ERP system is often operated by personnel with inadequate education in ERP in general, such as APICS foundations, and in the particular ERP vendor package being used. Personnel turnover; companies can employ new managers lacking education in the company's ERP system, proposing changes in business practices that are out of synchronization with the best utilization of the company's selected ERP. Chapter2 21
Welingkar’s Distance Learning Division Disadvantages Customization of the ERP software is limited. Some customization may involve changing of the ERP software structure which is usually not allowed. Re-engineering of business processes to fit the "industry standard" prescribed by the ERP system may lead to a loss of competitive advantage. ERP systems can be very expensive to install. ERP vendors can charge sums of money for annual license renewal that is unrelated to the size of the company using the ERP or its profitability. Chapter2 22
Welingkar’s Distance Learning Division Disadvantages Technical support personnel often give replies to callers that are inappropriate for the caller's corporate structure. Computer security concerns arise, for example when telling a non-programmer how to change a database on the fly, at a company that requires an audit trail of changes so as to meet some regulatory standards. ERPs are often seen as too rigid and too difficult to adapt to the specific workflow and business process of some companies—this is cited as one of the main causes of their failure Chapter2 23
Welingkar’s Distance Learning Division Disadvantages Systems can be difficult to use. The system can suffer from the "weakest link" problem—an inefficiency in one department or at one of the partners may affect other participants. Many of the integrated links need high accuracy in other applications to work effectively. A company can achieve minimum standards, then over time "dirty data" will reduce the reliability of some applications. Once a system is established, switching costs are very high for any one of the partners (reducing flexibility and strategic control at the corporate level). The blurring of company boundaries can cause problems in accountability, lines of responsibility, and employee morale. Chapter2 24
Welingkar’s Distance Learning Division Why do ERP projects fail so often? At its simplest level, ERP is a set of best practices for performing the various duties in the departments of your company, including in finance, manufacturing and the warehouse. To get the most from the software, you have to get people inside your company to adopt the work methods outlined in the software. If the people in the different departments that will use ERP don’t agree that the work methods embedded in the software are better than the ones they currently use, they will resist using the software or will want IT to change the ] software to match the ways they currently do things. This is where ERP projects break down. Chapter2 25
Welingkar’s Distance Learning Division Why do ERP projects fail so often? Political fights erupt over how—or even whether—the software will be installed. IT gets bogged down in long, expensive customization efforts to modify the ERP software to fit with powerful business barons’ wishes. Customizations make the software more unstable and harder to maintain when it finally does come to life. The horror stories you hear in the press about ERP can usually be traced to the changes the company made in the core ERP software to fit its own work methods. Because ERP covers so much of what a business does, a failure in the software can bring a company to a halt, literally. Chapter2 26
Welingkar’s Distance Learning Division Why do ERP projects fail so often? But IT can fix the bugs pretty quickly in most cases, and besides, few big companies can avoid customizing ERP in some fashion— every business is different and is bound to have unique work methods that a vendor cannot account for when developing its software. The mistake companies make is assuming that changing people’s habits will be easier than customizing the software. It’s not. Getting people inside your company to use the software to improve the ways they do their jobs is by far the harder challenge. If your company is resistant to change, then your ERP project is more likely to fail. Chapter2 27
Welingkar’s Distance Learning Division Common Causes of Disaster There are several common causes of disaster while implementing the ERP system. 1. 2. 3. 4. 5. 6. 7. 8. Change management & training Poor planning Underestimating IT skills Poor Project management Technology trials Low involvements of top executives Underestimating resources Insufficient software evaluation Chapter2 28
Welingkar’s Distance Learning Division ERP: Lifeline of modern Organization An ERP is a multi modular computer application, which is designed to support all the key activities of an enterprise in integrated fashion. It is a waste of time to reenter data over again It is very likely to be entered incorrectly. Data that results from very different disconnected applications is inconsistent, so attempts to analyze it yields the proverbial "apples and oranges"—a decision-support fruit salad. Chapter2 29
Welingkar’s Distance Learning Division ERP : Lifeline of modern Organization With an integrated ERP suite, there is a "single version of the truth" that only needs to be entered once to be propagated to all parts of the business that need it. All business processes, all employees who touch the application, and all the executives who make decisions for the company see the same version of reality, in real time, all the time Your business is more than internal operations: to be successful, you need to efficiently manage your own purchases of goods, services, and raw materials. Chapter2 30
Welingkar’s Distance Learning Division ERP :Lifeline of modern Organization Foster and control your relationships with your suppliers and your business partners; and create, manage, and retain your customer base. All these relationships are more efficiently and economically managed with business-wide applications. Look at that "order-to-cash" example; there are many steps that involve the customer, external delivery services, and the bank—all external to your organization. Chapter2 31
Welingkar’s Distance Learning Division ERP Strengths & Weaknesses End of Chapter 2 Chapter2 32
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