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Industry

Foundry

No other European country produces as many cast products as Germany.

The technological expertise of German foundries and German castings are highly regarded worldwide.
The foundry industry in Germany is considered a medium-sized business sector. Today, the iron foundry sector employs approximately 600 people, while the steel and non-ferrous metal foundries employ around 70,000.

Although the foundry industry, with a share of approximately one percent of total manufacturing output, is only one of the smaller German industrial sectors, its economic importance is generally considered to be far greater due to its role as a supplier.

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AvERP in the foundry

Planning and calculating production processes is one of the biggest challenges in foundries. At the same time, precise planning is crucial for cost-effective scheduling of castings. AvERP helps to transparently manage these complex processes, calculate accurately, and identify bottlenecks early on.

Rising energy and raw material costs, as well as the requirements for operational and machine data acquisition, further increase the need for digital solutions. AvERP offers integrated functions for this purpose, to control consumption, automatically collect data and efficiently manage manufacturing processes.

As an industry-specific ERP solution, AvERP links all relevant areas – from production and materials management to costing and quality assurance – in a central system. In this way, AvERP contributes to the future-oriented process optimization of foundries.

Advantages of the German foundry

In general, German foundries have a number of advantages over their competitors in other countries.
These include, among others:

  • Sound expertise and innovative capacity
  • Reliable supply and high production
  • Participation in simultaneous engineering projects
  • high logistics performance
  • high quality standard of the products

A special feature of the foundry industry: Heterogeneous single-unit production

Casting remains a highly individualized shaping process capable of producing virtually any conceivable form. The various materials and casting methods all serve to offer the desired material properties and shapes depending on the intended application. The most common materials are gray cast iron, cast steel, and ductile iron – these are primarily used in mechanical engineering and shipbuilding. Non-ferrous materials such as aluminum or magnesium are mainly used in the automotive and aerospace industries. Furthermore, a wide variety of sub-alloys are used as special features. Generally speaking, the demands on the quality of castings have increased significantly in recent years. Since the foundry industry still focuses more on individual production than series production, this sometimes presents experienced production staff with considerable challenges.

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Individual functions for the foundry industry

Generally speaking, with ERP systems, there are different ERP solutions depending on the type and size of the business, each with individual features to meet your needs and wishes.

The industry-specific software system for foundries generally features a large number of individually developed functions that were specifically designed for the internal characteristics of the industry.

Batch classification, formulations and batch tracking

The primary goal of batch optimization is to use a tool to enable the economical use of expensive input and additive materials, such as sheet metal bundles or pig iron, while still meeting the required quality parameters.
By employing a modern mathematical method, your foundry can identify the absolute minimum costs within predefined constraints, thereby achieving sustainable financial savings.
The weighing and analysis data are transmitted from the batch scale to the ERP software system via specific online interfaces.

Assessment of manufacturing risk

Controlling production and assessing production risks is generally one of the most crucial tasks for a foundry.
This includes monitoring and ensuring compliance with quantity, quality, and costs.
Our software solution, with its customized tools and functions, is specifically designed to meet the needs of a foundry.
Our system manages everything from pattern preparation to core making, molding, casting, demolding, and quality control.

Different evaluation options for the annual business planning of the foundry operation

Our ERP software system can be used in precision foundries, metal foundries, iron foundries, and die-casting foundries, among others. The software solutions are suitable for both smaller companies with few employees and larger enterprises.
We maintain constant contact with foundry companies and continuously develop our ERP system in collaboration with them.

Integration of multiple locations

If your foundry has multiple locations, an ERP system can be a great advantage for your operations and significantly simplify internal processes. With our software solution, you can share all documents across different locations, thereby creating maximum efficiency and transparency.

Planning department (PPS)

In the planning phase, ERP software allows for easy planning with changing resources, such as alternative machines. The costs of these alternative machines are automatically factored into the feedback.

Extended workbench

Special tools can be used to outsource foundry-specific processes (blasting, cleaning, cutting, annealing, etc.) to external service providers.

Capacity planning

The Employer Resource Planning System considers core making independently of casting dates and therefore plans the times and deadlines individually.

Financial Accounting

With the help of an integrated financial system, your foundry can handle the entire quoting process via ERP software. This creates greater cost transparency for all parties involved in the commercial side of the business. Furthermore, the financial accounting department handles all balance sheet preparation and current account transactions and is also responsible for dunning and payment processing.

Document management system

Our ERP software solution features an integrated document management system that allows documents to be easily stored via drag and drop.

Cost control

The foundry industry, in particular, requires a highly efficient cost accounting system. This is primarily due to the highly specialized, one-off production and the heterogeneous use of materials within the foundry sector.
It is crucial that cost control relies on a differentiated and flexible allocation rate system.
Using the cost accounting function of a modern ERP system, the actual markups and allocation rates for each individual product are calculated.
Internal performance forecasting is also readily achievable through cost accounting.

Conclusion – ERP system for foundries

With industry-specific ERP software, all processes in your foundry, from order entry to invoicing, can be seamlessly mapped, structured, and monitored. In the long term, the ERP software system also proves to be a significant business management tool, enabling you to successfully analyze your company’s financial data from various perspectives. Our ERP solution not only creates greater transparency in your operations but also allows you to respond flexibly to all customer requirements and energy price fluctuations.

Other industries of AvERP

Automotive

Service provider

Single-unit production

Electrical engineering

Wholesale

Retail

Craft

Industry

Food industry

Logistics

Contract manufacturing

Mechanical and plant engineering

Medical technology

Series production

Injection moulding and plastics

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The license-free ERP system for small and medium-sized enterprises.

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Support: +49 (0) 921 / 60 800 93-45

Office: +49 (0) 921 / 60 800 93-0

E-Mail: info@synerpy.com

Address

SYNERPY GmbH

Christian-Ritter-von-Langheinrich-Straße 7

95448 Bayreuth

SYNERPY GmbH

Chr.-Ritter-von-Langheinrich-Str. 7

95448 Bayreuth

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