ERP Selection Methodology for Metal Sector
ERP Selection Methodology for Metal Sector
Abstract
When a firm decides to implement ERP softwares, the resulting consequences can pervade all levéis, includ-
ing organization, process, control and available information. Therefore, the first decisión to be made is which
ERP solution must be adopted from a wide range of offers and vendors. To this end, this paper describes a
methodology based on multi-criteria factors that directly affects the process to help managers make this de-
cisión. This methodology has been applied to a medium-size company in the Spanish metal transformation
sector which is interested in updating its IT capabilities in order to obtain greater control of and better infor-
mation about business, thus achieving a competitive advantage. The paper proposes a decisión matrix which
takes into account all critical factors in ERP selection.
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Customer A ^^^^^^^^^^^^^^^^^^^^^^_
Customized
Processes Special Process Out of Scope
Requirements
Industry
C o in mon ^^^^^^^^^^^^^^—^^^
Processes
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E R P core functionality E R P non core functionality
The most intense work load is normally the identifica- Step 4 -Analysis of offers, costs involvedandresources
tion of processes. First, the global function involved in the needed
implementation scope must be identified. For example, When the offers are received, all aspeets of them must
inside purchasing we must consider all the general ac- be analyzed: the responses to special requirements, the
tivities or sub-processes: orders documentation, mainte- resources proposed, the range of costs, and the imple-
nance providers, delivery times, non-storable produets mentation plan, including time, work load and resources
such as transports, etc. For each sub-process, a flow chart involved. After this analysis, any doubts must be identi-
has to be designed to identify the decisions involved, the fied and the questions resent to the ERP vendor.
beginning and end of the process, and the interactions It is important to remember that errors may oceur;
with other processes. At this point in the project, col- therefore, our summary for each ERP vendor must be
laboration between management and workers is important revised by other colleagues.
because a correct identification and defmition of proc- Step 5 - Selection and procurement of licenses
esses will help in all steps of the implementation. Once the ERP vendor has been selected, the next step is
Finally, a spreadsheet with the all sub-processes is to initiate negotiations to adjust licensing, prices, the
made up, with a flow chart of each sub-process and an maintenance contract, and actualization issues. This final
explanation how it works. It is important to identify a step must comprise all points of our criteria to ensure a
short ERP vendors list which can be managed comfortably. global context implementation and specify the teams
Step 2 - Criteria to be evaluated and RFP involved, the people in charge, the schedule and penalties,
In this step, a criteria evaluation must be generated ifneedbe.
together with a weighted column of those points that Another critical aspect is the communication of deci-
should be determinants in the implementation, such as the sions to the entire company, keeping workers informed of
completion of the initial processes list, technology archi- the schedule and scope, especially those affected by
tecture needed, cost and duration of implementation, strategic tasks inside the company. Resistance to change
maintenance, training. The weights are assigned accord- is always a critical aspect in the implementation period.
ing to the firm's needs, priorities and overall objectives.
After this step, a Request for Proposal (RFP) is devel- 4. The Methodology Approach
oped with all criteria that must be evaluated, with an ex-
planation of the requirements about compliance or devia- The case study is focused on a médium size company (20
tions, the vendor's assumptions, implementation success workers) in the Spanish metal transformation sector
experiences and pricing. Finally, the RFP must be sent to which was interested in updating its IT capabilities to
all the ERP vendors included on the list. attain greater control of and better information about
Step 3 - Compile questions and responses for the RFP business, thus achieving a competitive advantage. The
The purpose of this step is to answer the ERP vendors' approach represents step one and two of the methodology
questions and to be sure that all requirements are under- in a real situation.
stood correctly. Afterwards, all ERP vendor responses
must be compiled into the RFP and the implementation 4.1. Characteristics of the Firm
alternatives, solutions for special processes, and applica-
tion requirements given by the vendors studied. The company is completely automated having highly
Once this step has been completed, ensuring that spe- robotized production lines. It has two business lines. The
cial requirements, alternatives and technical solutions are first produces standard produets, with a yearly demand for
checked, different demos should be prepared with each large quantities at a low cost. The second is focused on
vendor to clarify any weak points. After the pilot is pre- projeets on-demand, with engineering, design, prototype-
pared, and all the information is compiled, the complete ing and a short life eyele. The response time must be
offers are ready to be evaluated. expeditious, with delivery in 24 hours.
The customers are mostly local firms. The company hard disk).
needs to be as cióse to them as possible since the cost of • Work orders are not automated. Workers must
transportation represents a significant expense and the know what is needed in order to manufacture an
quantity and price of each order is not high enough to order.
offset this cost.
One of the main characteristics of the metal processing 4.3. Scope and Requirements
sector is that it is very sensitive to price. Because of this,
the size of the company is crucial to obtain the best pnces Our aim is to intégrate all applications and departments
from the suppliers and the best manufacturing volume. Its in two phases. The first will consolidate all applications,
main suppliers are major steel producers or processors. except accounts software. When the operation is success-
This makes it necessary to acquire large volumes of raw ful, the second phase will include accounts.
materials to achieve a competitive discount advantage. Once this scheme has been approved, all the processes
The interaction between these two aspects makes a mé- must be analyzed and adapted to the functionalities and
dium size optimal for a company in this sector, as statis- characteristics of the ERP software, with the help of the
tics show. people in charge of each process. Everyone in the or-
The organization within the company is a typical func- ganization must be involved to ensure that all types of
tional organization, as shown in Figure 5, with each de- eventualities have been included. The new flow chart of
partment in charge of its own functions. the company is reflected in Figure 7 and represents how
the processes will be developed after this analysis.
4.2. Software and Functionalities The ERP software design includes finances, sales and
distribution, CRM, e-commerce, purchasing (MRP and
The analysis of the business operation in terms of installed MRPII), stock management and operations support inside
applications shows the existence of different applications a unique system, all integrated. After a first contact with
in each of the functional áreas (purchasing, production, different vendors and software, we noticed several Solu-
sales, etc), but no information flow between them. This is tions with different license approaches:
evident from the map of applications reflected in Figure 6. • Property license such as Microsoft Dynamics Nav,
The firm operates using the foliowing applications: SAP Business One and JD Edwards.
• Purchasing software in MsAccess with local data • Open Source (GPL license), such as Abanq and
(internally developed). OpenErp.
• Sales software, with local datábase, also in MsAc- • Public licenses that restrict some aspects of the use
cess and no link between any other programs or or distribution, such as Open Bravo and Compiere.
datábase (externally developed). Following the analysis, we identified which processes
• Operations control and productivity with written fit with a standard flow (supported) and which had to be
weekly reports (no software, done manually). customized initially (Table 2). For example, the pro-
• Stock control (no software, controlled manually). cesses relating to Calculation of Estimated Cost of existing
• Material Requirements Planning (MRP) (done producís, or Reserve Stock, meet the standard require-
manually, aided by spread sheets written by the ments offered by a commercial ERP and required no
Technical Department, and stored on a common customization. On the contrary, the processes related to
General Manager
Sales Dpt. Purchasing Dpt. Technical Dpt. Production Dpt. Finantial Dpt.
Stock
Operators
Management
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Management
Purchasing
Split components X
Reserve stock X
Múltiple request X
Partial deliveries X
Suppliers management X
Price update
Order Tracking
Technical definitions
Components
Work Orders
Sales
Track orders X
Drawing and Codes, and Price Updates needed complete Time and Cost, and others.
customization because they were not standard. That is In order to keep the case study from becoming too
also the case of Estimated Time of Delivery, Differences lengthy, we will focus on only three critical processes:
between Orders and Deliveries, Deviation from estimated Purchasing, Proposal Management and Work Orders. A
greater level of detail is required to customize the active- each external link is critical and represents one of the most
ties that must be developed for these processes. risky aspects, we must be sure to cióse all sources of the
Each process had to be analyzed at length to ensure its information flow so that the ERP doesn't lose control
fit with the standard, and if it did not, it became a new every time the flow gets out of the system (Figures 8, 9
development project within the implementation. Because and 10).
Purchasing
Request
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New client order múltiple
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suppliers
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Management of
Management
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Quality
and delivery
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question department initial materials and
development machinery
Estimated Estimated
Proposal Price
delivery time structure
calculator
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final product Manufacture Machínery Load
stock
Personnel
Management
From the analysis of all features included in the pro- redesigned according to this initial information.
cesses stands out a set of applications that needs to be Purchasing Process
studied in detail for customizing according to their own • The differences between ordered and delivered
requirements. quantities must be managed by the system. It must
Process for the Management of Proposals permit changes and recalculate all costs. Also, any
• The management of proposals must be flexible and returns must be included.
take into account all versions and changes discussed • To ensure that price given to the clients fits with the
with the client before the order is finalized. internal costs, the system should handle this infor-
• Regarding estimated delivery time, the ERP must be mation and analyze deviations. When the prices of
able to provide information about the work load and spare parts or raw materials are updated, the sys-
machinery that will help to analyze future delivery tem must be able to recalculate the cost elements
times. Optionally, the system could give an esti- involved.
mated time. • Work Orders Process
• Creation and valuation of non-existing products is a • The most important aspect in this process is to in-
major development because it collects the special tégrate the management of labour so that this in-
requirements of future developments or never pro- formation can be used as a reference for the rele-
duced products that must be budgeted. The most vant indicators such as productivity, absenteeism,
efficient way to budget non-existing products is to etc., and to narrow the initial time estimation. It
use the time frame estimated by the person in charge must include a control of deviations from estimated
of proposal, with advice from the technical de- time and the surveillance of workers.
partment if necessary, and the costs of the machin- • This application includes information which is
ery and workers estimated by the ERP. If the pro- needed in the report used in the work order.
posal is approved by the client, the order must be All the other processes (Sales and Technical definitions)
required for an efficient ERP design also require a set of weights were established by the management staff, ac-
applications that need to be customized. In the sales cording to the IT department and consultant's analysis
processes, the major problem reported by workers is the (Table 3).
constató updating of the order by the customers, and its
implications. This suggests the need for constató real-time 4.5. Analytical Hierarchy Process Method (AHP)
information between client sales and manufacturing on
the state of the order. The sales department must also An alternative comprehensive method has been proposed
ensure that tracking the order is always possible. by Saaty [23]. It determines the priority of a set of alter-
Finally, the integration of the system with the technical natives and the relative importance of attributes in a múl-
department requires a specific design of drawings and tiple criteria decision-making problem. It has been used in
code applications. various applications such as information system selection,
as well as ERP selection [24].
4.4. Concept Evaluation. Decisión Matrix and The basic approach of this method relies on building a
Evaluation Criteria hierarchy of all objectives derived from the strategic
analysis in order to distinguish fundamental-objectives
Once all processes have been analyzed in accordance with from means-objectives. The former being those that de-
the requirements identified in the flow of information, it cisión makers really want to accomplish while the latter
will be possible to decide which provider and alternative are those which help the fulfillment of other objectives.
of ERP will be best. All requirements should be listed on Consequently, fundamental-objectives are organized into
a spreadsheet with the information collected from the a hierarchy which will help the decisión makers in order
ERP vendors, the demonstrations, and our general im- to identiíy the relevance of ERP attributes. Thus, the
pressions. priority of alternatives can be obtained by aggregating
The Concept companson and Evaluation proposed by the weights over the hierarchy. This can speed up the
Pugh [22] is a well known and referred method for con- development of a consensus in relation to the ERP sys-
cept selection. It is based in the selection of the evaluation tem and vendors alternatives [24]. The Figure 11 illus-
criteria for the concepts. The spreadsheet with the dif- trates this selection alternative.
ferent main aspects must be organized to collect the im- In relation to ñindamental-objectives, it must be taken
pressions from employees in each functional department, into account the limitations of decisión factors and the
on usability and user friendliness, in addition to technical changing business environment. Means-objectives are
IT aspects and the costs involved. The decision-matrix is a usually organized into networks relating them (Le. flexi-
quantitative technique used to rank the multi-dimensional bility and ease of integration may be related with common
options of an option set and is a form of prioritization programming language, platform independence or system
matrix. The basic decisión matrix consists of establishing maturity). The set of ERP candidates and vendors can be
a set of weighted criteria upon which the potential options shortened by examining means-objectives and also de-
can be analyzed, scored and balanced to obtain a score velop detailed attribute specifications to assess the ERP
ranking. These scores are organized in order to rate each systems. Alternatives for attributes and inter-attribute
concept, the higher the socre the higher its compatibility. relative relevance can be converted into numerical scales
It is a useful iterative method for the comparison of in order to weight them.
alternative concepts.
The advantage of this approach to decision-making is 5. Conclusions
that subjective opinions about alternatives can be made
more objective. Another advantage of this method is that For a firm to gain competitive advantage, managers
sensitivity studies can be performed. The major advantage need to outline a set of objectives. Normally these object-
of this method is that it facilitates analytical and synthetic tives reflect both the business drivers and the market.
thinking and that new concepts can be generated as a Conversely, firms are facing significant challenges in
consequence. order to become suppliers of larger customers due to the
In reference to the firm being analyzed, six principal excessive costs associated with accessing a vast market of
aspects were identified: standard compliance, develop- potential customers. For these reasons, it is essential for
ments compliance for software adaptations, solutions companies to adopt an ERP system to maintain control of
offered by the different departments of the firm for criti- their operations and to compete globally. An ERP im-
cal issues reports, skills and confident in the demonstra- plementation is expensive and risky for all businesses, but
tion, technical requirements and fit with the IT depart- it is even more challenging for small businesses, which
ment, and finally cost involved. The main and secondary have particular characteristics.
Table 3. Case study of a decisión matrix.
~ 1 "
I
Screen out the unqualified
Form the AHP model
ERP systems
Despite the great potential and popularity, the adoption the design of the software, constitutes a key factor that
and implementation of an ERP is compromised by re- can contribute to reducing these failures. But the integra-
markable failures. While many studies highlight the ex- ron and standardization imposed by most ERP software
istence of different factors, we argüe that the integrated may not be suitable for all types of firms. Thus, the fit
nature of the ERP, which generally requires an organiza- between the characteristics of the adopting organization,
tion to adopt standardized business processes reflected in and the standardized business process designs embedded
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Most metal transformation companies are small-sized, with less than 10 employees accounting for 83% of the sector . This size distribution impacts ERP implementation as small firms may have limited resources and require scalable solutions tailored to their size and processes. The fit between ERP solutions and company size is critical for successful implementation, necessitating careful selection and customization to ensure that the standard processes embedded in ERP systems align with the business processes of small companies .
Firms face challenges integrating ERP systems with existing applications due to the lack of information flow between different applications used in functional areas. For instance, many companies use disparate systems like MS Access for purchasing and sales, which are not linked, leading to fragmented data across departments. Integration is further complicated if some areas are not included in the ERP scope, requiring data integrity assurance between the new and old systems . Thus, firms must ensure that all applications and processes are thoroughly analyzed and adapted to the functionalities of the ERP to achieve successful integration .
The primary activities in a metal transformation company include purchasing, sales, production, stocks, and financial operations. For purchasing, the processes involve orders, partial or total deliveries, price or quantity variations, consultation of prices, stock availability, reserved stock, and management of providers. Sales activities comprise quotations, delivery times, sales prices, new products, customer relationship management (CRM), client discounts, and special offers. Production includes operations and production orders. Stock management covers the valuation and cost of stock (average, medium, LIFO), reserved or available stock, automatic reordering at minimum stock levels, minimum stock warnings, raw materials, stock devaluation, and obsolete stock. The financial activities involve accounts, fixed assets, taxes, bank communication, structure, and data imports from past years .
Having a clear scope definition before starting an ERP implementation project is imperative to ensure that the project aligns with the company's strategic objectives and operational requirements. A well-defined scope helps in identifying all the processes that need to be included in the ERP, ensures proper allocation of resources, and prevents scope creep, which can lead to budget overruns and timeline delays. It also clarifies the geographical and functional requirements, helping in the selection of an ERP that satisfies the multi-country or multi-language needs of the organization .
Employee experience plays a significant role in ERP system implementation decisions as it influences the usability and acceptance of the new system. Employees with prior experience can contribute valuable insights, assist in identifying key process gaps, and provide training to other staff members. Their familiarity with existing applications aids in mapping current processes to the new ERP system, facilitating smoother transitions. Ensuring that employees are engaged and their concerns addressed during the selection process can mitigate resistance and enhance implementation success .
Customizing ERP processes involves both risks and benefits. On the one hand, customization allows a metal transformation company to tailor ERP functionalities to better fit its specific business processes, potentially leading to greater efficiency and competitive advantages. On the other hand, it poses risks such as increased costs, extended implementation times, and potential complications in future system upgrades if the customizations are not well-documented or supported. Additionally, over-customization can compromise the system's integrity and cloud the benefits of using a standardized system. Thus, firms must carefully balance the level of customization they undertake .
Companies should follow a systematic methodology involving several strategic steps for successful ERP adoption. Initially, it involves determining the scope and requirements of the ERP project, ensuring a thorough understanding of what will be developed and replaced. Next, companies need to analyze which processes fit into standard ERP flows and which require customization. Engaging employees, motivating them, and utilizing their knowledge to inform decision-making are crucial. Decision-making should be based on multi-criteria factors affecting company processes, and a decision analysis methodology should be followed to ensure ERP solutions align closely with organizational needs .
The ERP system selection process often differs between small and large enterprises due to varying resource availability and complexity of operations. Small enterprises, which form the majority in the metal sector, might prioritize cost-effective solutions with core functionalities, focusing on scalability and adaptability. In contrast, large enterprises may require more comprehensive systems capable of handling complex and integrated processes across multiple departments. The selection also involves assessing the ease of customization to match distinctive business processes and ensuring that the selected ERP aligns with the firm's existing IT infrastructure and organizational goals .
The evaluation of ERP systems in the metal products industry should encompass various factors including the alignment with core business processes, scalability, ease of integration with existing systems, customization capabilities, cost-effectiveness, and support for multi-country and language needs if applicable. The system's ability to support standard functions without extensive customization and facilitate information flow between previously isolated departments is critical. Furthermore, the choice of ERP should consider organizational culture, readiness for change, and employee adaptability to new systems, ensuring a holistic appraisal that goes beyond technical specifications .
Standardized business processes embedded in ERP systems can significantly affect implementation success by ensuring consistency and efficiency across departments. However, they can also pose challenges as they require organizations to adapt their existing processes to align with the ERP's predefined processes, which may not be suitable for all types of firms. If there's a poor fit between the standardized processes and the company's operations, it can lead to implementation failures. Therefore, the success of ERP implementations often depends on the extent to which firms can customize the ERP to meet their unique process requirements .