Overview
Renuka Tools was founded in the year 2000 in Aurangabad, India with its vision to be the preferred special cutting tools provider. Renuka Tools with its state-of-the-art manufacturing unit that produces high-quality special indexable cutting tools with utmost precision using the latest technology and highly skilled and technical manpower. All cutting tools manufactured at Renuka come with a Zoller Report, ensuring that the global export quality standards are met, guaranteeing complete customer satisfaction.
At Renuka Tools, their core expertise is in manufacturing special customized cutting tools. They also offer standard products such as:
- Micro Bore Units
- BCA Finish Boring Bars
- Boring Kits
- Eccentric Fine Boring Tools
- Adjustable Boring Tools
When its legacy application couldn’t handle its fast growth, Renuka switched to e-Whiz Global’s Whiz Synergy ERP & Whiz Sales CRM for its manufacturing, CRM & mobile functions.
Situation and Challenges
Tool manufacturing is a highly competitive industry where timely and accurate quoting, production, invoicing and payment collection are major challenges.
It was difficult for the Renuka team to track different designs & drawings for their tool and job work service. Every order had unique technical specifications. This made quoting the right price to the customer with clarity on direct and indirect costs a big challenge.
An operator was having difficulty understanding the operations to be performed on a cutting dimension for a specific order caused by mismatched drawings and ever changing priorities. This resulted in delays in manufacturing and missed on-time deliveries.
Based on sales delivery promises, the dynamic manufacturing environment had few of the operations outsourced thus making it difficult to plan and track work in process with outsourced vendors. Raw material planning per demand for required dimensions was a major challenge. Procuring the right material at the right time and price was critical.
Another complex part was tool and tool breakage traceability, as 10% of fixed assets are used during manufacturing processes. Operators would often break, lose or misplace tools. Renuka was looking for tool traceability and availability.
A robust, cost efficient system to handle all of these challenges was needed. e-Whiz Global had the solution.
Solution & Benefits
Whiz Synergy enabled the user to report stage and operation production along with a defined separate locator for each operation. Semi finished goods were tracked in real-time.
The E-whiz Global team Implemented the solution from front to end, greatly enhancing systematic production processes with quality checks, brought system efficiency up, and allowed users to inspect produced material at every stage as per defined quality parameters. This greatly improved the quality of finished material, meeting or exceeding technical specifications. This now allows Renuka to process custom orders as per customer requirements.
Job orders are now linked to their respective engineering design & drawings, allowing access on the shop floor using mobile devices. The operator now looks at the sequence of scheduled work orders for a particular machine, performs production and captures it in the system in real time also using mobile devices.
The implemented solution optimizes the stock picking process by organizing the warehouse using designated stock locators, making it easy to retrieve materials when needed. The solution enables tracking of all inventory movements for subcontractor’s locations and track work in process with vendors.
Integrated workflows gave overall visibility of departments within the plant including individual responsibility with status detail.
Approval workflows were defined in such a way that approvals are done based on currency limits and hierarchy. This has increased productivity and reduced time spent on manual approvals. Real-time status of the customers orders are now available with customer support. High productivity and enhanced quality became standard process.
Fixed asset and tool tracking are now easy with full transparency including availability, current ownership, and tool returns.