The Powder Web application was developed for Techno-Coat, Inc., a powder coat solution
provider in West Michigan. Powder Web is an Enterprise Resource Planning (ERP) application
used by everyone in Techno-Coat. The Powder Web application was a new application developed
to replace a purchased application.
This application provides complete ERP for Techno-Coat, including order entry, production
scheduling, shop floor reporting, shipping, and invoicing. It also includes inventory,
purchasing, receiving, quoting, and quality control systems.
Recipe (Bill of Material and Manufacturing Operations)
The core of the system is the inventory and production control. Parts are received and
either placed into inventory or directly in the production line, depending on the production
schedule. The shop floor schedule is the key. This is where we need to quickly access all
production-related information and keep everyone in the operation informed.
As parts are needed, the schedule is used to pull parts from inventory. This creates a paper
traveler that stays with the parts and enables the people pulling material from inventory to
know where to get it. The paper traveler also acts as the identification for that group of
parts. With the Powder Web application, the processing instructions for the parts can be pulled
up by the paper traveler or any terminal on the shop floor as the parts are processed.
The traveler and the quick links on the schedule allow role-base viewing of the processing
instructions. The software is set up so that the routing and bill of materials are predefined.
Some material goes on for final assembly, while other product gets ready for shipping to the
end user. Because of this, we need flexible labeling and documentation that allows us to
react to the greatly different shipping requirements. Labeling is applied in production,
and a single barcode scan allows parts to be shipped with almost no user input other than
scanning the material as it is loaded onto the truck.
Shipping screen
We set up documentation to ensure customers receive goods from shippers best suited for
their needs. This data is a direct input into their system and includes various electronic
methods as well as traditional paper.
Once a shipment is made, all information transfers to the accounting and custom invoicing
parts of the system. Our customers have diverse invoicing requirements. The Powder Web
application allowed us to develop a flexible invoicing process. We invoice quickly yet
differently to each of our customers. Some never receive invoices, others get custom
electronic files, and a few still get paper invoices.
Production schedule
Once invoices are created, a summary file is sent to the MAS90 accounting software for
GL and financial reporting.
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