Case Study Efficient Order Processing and Fulfillment at LÄPPLE
For more than two decades, PSI's ERP and MES solutions have mapped the entire process chain at the Heilbronn-based company – despite constantly changing processes.
The international LÄPPLE Group has been using the PSIpenta ERP system and various ERP extension and MES modules since 1998. During this time, the company and its IT solution have had to be highly agile and flexible in the face of constantly changing markets, competitive situations and technologies.
About the LÄPPLE Group
The globally operating companies of the LÄPPLE Group (Läpple) primarily develop and produce components and solutions along the value chain of the automotive industry. Läpple Automotive, for example, is a forming specialist for high-quality components for premium vehicles, Fibro Läpple Technology is a specialist for intelligent automation solutions such as axis and portal systems, and Fibro Normalien is the European market leader in toolmaking.
The family-run group of companies employs around 2,200 people worldwide and counts the who's who of the automotive industry among its customers, as well as well-known companies in the mechanical engineering and tool manufacturing sectors and their tier 1 suppliers.
Challenges
Läpple has to continuously face the challenges of the markets and customers. This includes, for example, expansion into new markets, taking into account local specifics, optimizing production logistics to reduce inventories and tied-up capital, and streamlining planning and production for the efficient processing of large-scale orders.
Production Characteristics
- Taking into account country-specific features in various countries in Europe, Asia and the USA
- Meeting the strict requirements of automobile manufacturers
- Mapping processes in toolmaking as well as in series and large-scale production
Läpple's objectives
As a versatile group of companies, Läpple was looking for an ERP solution that offers a high level of functionality in the system standard and has an open system architecture for connecting third-party systems, as well as a high degree of scalability. Last but not least, the ERP system should offer the necessary flexibility to be adaptable quickly and easily to changing conditions, for example, to connect further branches in other countries or to streamline processes for efficient large-scale production.
The main objectives
- Implementation of a central data hub in the group of companies across plant and national borders
- Covering as many processes as possible in the individual companies in the system standard
- Openness to the connection of third-party systems
- High scalability
- Easy adaptability to changing conditions
Approach
In PSIpenta/ERP, Läpple has opted for an industry solution that has made a name for itself in discrete manufacturing – in the automotive and supplier industry as well as in mechanical and plant engineering. To integrate the workshop level, modules from PSIpenta/MES can be easily integrated and high-performance products from specialized partner companies can be added for special requirements.
Realization
At Läpple Automotive alone, 800 users work with the system, which maps the entire process chain there – from incoming orders to shipping and invoicing. Further systems are connected via interfaces, including SAP financial and asset accounting, a Microsoft CRM system and archiving solutions from PSI partner Intex.
An important step in the context of the expansion towards the USA was the introduction of the ERP module Multisite for multi-plant control. This enables Läpple to map the various companies independently on the one hand, while controlling them efficiently at the same time.
Result
Internal specialization gradually reduced
The LÄPPLE group has constantly changed over the years. Its IT, especially the ERP system, has not only supported the changes and growth, but has also helped the company through some difficult times. “In retrospect, we made the right decision at the time, because you don't just change an ERP system,” says IT project manager Hans-Peter Rudolph. “This makes factors such as scalability and flexibility of the solutions all the more important - and, of course, the flexibility of the manufacturer itself.”
For example, the streamlining of production and the reduction of batch sizes not only minimized inventories. From the point of view of those responsible, it is also repeatedly valuable that applications are included in the standard. This has made it possible to replace numerous protocols over time and gradually reduce internal specialization.
Conclusion
The agility of companies in changing markets is a decisive factor for long-term success. Large companies in particular are highly dependent on the technological basis and functional performance of their IT systems. In PSIpenta/ERP, Läpple has found a system that allows the group to make and adjust adjustments or additions quickly and easily, enabling efficient planning and control of processes across plants and countries.
