Every order is unique. Every day.

If you create specialized machinery, plant machinery or plants, you find yourself faced with new challenges all the time. Your projects are immensely complex and require extremely intensive collaboration between all departments. It’s essential that you develop a clear estimate of the total cost of each product that you’re manufacturing – especially in the modern environment, where calls for tender come with ever shorter deadlines: you still need your business to be profitable at the end of the day, even as complexity snowballs. You need a flexible, scalable solution – such as our PLC-COCKPIT, which integrates perfectly with your other SAP components.

Flexibility and security when tendering

Sometimes, your customers may want quotes for machinery and plants that you don’t yet have a well-established data basis for. Working with specialists from construction, manufacturing, procurement and sales, you collaborate to develop an accurate cost calculation for the quote.

PLC-COCKPIT gives you the flexibility and security of customization tailored to your product costing – while leaving your users plenty of degrees of freedom to ensure timely costing results can be obtained even if no master data is available. Plus, of course, you can structure and display your quotes individually. PLC-COCKPIT makes full use of a well-founded data basis from your ERP system and a system of costing templates. You can build on favorite cost scales, simple component costing, product feature modification (variant configuration) and target price costing to ensure you submit your quotes in plenty of time, while automatically improving your customer focus.

The big picture: deadlines and costs

You’ve won the tender. Parts lists are proliferating, and you need to use these to draw up work schedules and start production. Sales procures the initial materials, and as soon as possible, your production department starts work on the first approved parts and components. You begin allocating to subcontractors.

Over time, the system grows into a complex network of modules, components and assemblies for the final plant; you need to maintain an overview of these, linked to agreed deadlines and costs. PLC-COCKPIT ensures you have comprehensive cost-related documentation throughout the product creation process and cogent arguments for new cost evaluations.

Using the project-related postings of incoming goods and employer activities, the system is updated with the actual costs. You can use these to generate project progress and monitor milestones. As a result, you have the necessary transparency to react rapidly as soon as any difficulties threaten on the horizon.

Our MES CAT also acts as a central hub, collecting diverse information from production and bringing it together to process and visualize every event in your production systems. The result is a 360-degree overview of production, and the establishment of a valid data basis for further process optimization. You can see production-relevant data when it happens, analyze it and compare it with historical data. Any problems or non-conformities can be identified immediately, so you can react promptly.

For example, you can find out whether a particular machine, manufacturing product A, is currently using more resources than it did during a previous production run, or when it was manufacturing product B. These kinds of comparisons establish an important basis for improvements. Our tools ensure you are prepared for whatever your customer requirements are – even if the next client has a completely new request for you.

After-sales: building the customer relationship

Once you’ve completed all stages of the project, it’s time for the project costing analysis: how successfully did you handle the project? This is also the start of the service and maintenance stage. From the machine/plant number, you can identify exactly which components were included. Lists of wear and replacement parts help with materials planning. The individual service and repair processes combine into a plant history, so that you always have a clear picture of your product’s lifecycle.

As long as you calculated the product costs accurately and didn’t leave anything in production to chance, you can be confident that your product margins will be on target. With comprehensive digitalization and automation, you can efficiently exploit the optimization potential of value-adding activities in your production halls, and thus create real added value.

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Norbert Kytka, Headquarters Plattling