GRIRO SA

RATIONALE

GRIRO SA is the largest producer in Romania of complex process equipment used in the fields such as Oil & Gas, Chemicals and Fertilizers, Energy, Environment or Metallurgy. With a tradition of over 100 years in the industry, GRIRO is placed today among the well-known producers of process equipment worldwide.

The production system at GRIRO is of type "Engineering-To-Order" or "Project based production". The company’s products include processing reactors and process columns, vessels under pressure, heat exchangers, air coolers, pre-heaters, condensers and steam drums.

In the past, the company used certain IT applications for the management of activity, but did not have an integrated information system that would meet all its requirements, while the management has identified also the need for implementing Business Intelligence solutions as support in the decision making process.

In order to increase its competitiveness on a continuous changing market, the company’s management has identified the need for creating an instrument that would ensure the GRIRO’s performance, by creating an information system able to optimize the functioning of all organizational structures, at all levels.

CUSTOMER’S REQUIREMENTS

• flexibility, modularity, traceability, security, scalability
• managing the structured and unstructured data as well as documents
• managing the workflows, allowing the tasks’ routing and the associated documents in order to support the daily activity 
• defining the information flows according to procedures and configured depending on the users responsibility
• integration of all the business activities, both basic and support activities
• data transparency within the organization and improving the decision –making process
• proper instrument in the flexible planning and efficient monitoring of activities in all the functional compartments
• coherent, comprehensive, powerful and fast system for registering, processing and data and information analysis
• "intelligent" tool for getting the performance and analysis indicators, specific to any functional field, prognosis elaboration, „what-if” type of scenarios in a optimal time interval.

FUNCTIONALITIES

• Elaboration of bids for various types of products
• Flexible defining of the formulas for performing the cost estimates
• Bids’ versioning
• Running the provisional calculations (cost estimates) with the possibility of changing quotients directly from the bid screen Quick releasing of provisional calculations by different methodologies applicable depending on the types of manufactured products
• Detailed highlighting of the elements of an offer / bid with help of the report "Breakdown of the bid"
• Synthetic analysis of the offers / quotations with help of the report "Bid Summary"
• Interactive defining, with own GRIRO coding system, of the sub-assemblies and components
• Using the size-related properties when calculating the gross mass
• Generating the customized report "Record on constructive reviews /checkups"
• Generating the list of operations depending on the equipment type and dividing the labor hours per positions and jobs specific to GRIRO
• Automatic association of technologies when versioning them
• Releasing the materials summary based on the data from the constructive design
• Issuing the labor list
• Issuing the summary reports per services and the summary reports per components for further monitoring of the manufacturing
• Generating the "Record for recording the technological review (overhaul)"
• Using the partial launches for complex products
• Automatic generation of the materials requirements (requisite) in the Inventory application
• Automatic association of the collective resource (defined per position / job at GRIRO)
• Automatic takeover of the labor tariff from the bid, for the planned labor cost
• Generating the customized documents specific to launching into production: work orders, monitoring sheets, consumption notes, summary reports for consumption notes, labor summary reports
• Monitoring the centralized and detailed labor consumption, through customized reports: labor summary report, work report, customized report "Material Schedule", customized report "Materials List", customized report "List of replaced materials per orders"
• Managing the products reference directories per groups of products and product categories using dimensional properties (attributes) and automatic calculation of the factor of mass conversion
• Automatic cancelling of the materials requisite, the procurement requests and of reservations upon performing waivers (replacements of materials)
• Calculus of available (free) stock and generating the procurement request whether or not we are taking into account the available stock
• Generating customized inventory reports: Summary report on materials and the link to the procurement flow, Metal consumption and materials consumption (cumulated and detailed), List of reservations, Inventory on date
• Analysis of procurement procedures per simplified and complete flows
• Generating the request for proposals with centralization from several procurement requests and taking over the properties specified in manufacturing
• Generating reservations and taking over the specific properties at article and batch level, respectively
• Generating the purchase orders with centralization from several purchase requests and taking over the properties specified upon manufacturing
• Procedures for managing the requests for proposal by the suppliers, registering the offers from suppliers, launching the purchase orders with full management of the specific properties
• Generating customized reports on stocks - procurement "Analysis of prerequisites".

The solution of Business Intelligence, SIVECO Business Analyzer, provides support to the GRIRO management team in identifying the important market trends, in the decision making process for the planning, monitoring and control of activities and for adopting strategies for the cost control or profit increase.

SIVADOC, the system for the documents and workflows management, provides a common platform for connecting people, processes and information. The system accelerates and increases the efficiency of the organizational processes through the intelligent management of workflows and of all kinds of documents, irrespective of their manner of entry into the system or their nature.

ADVANTAGES

• increasing the degree of data consistency, coherence, relevance and correctness
• reducing the times for data processing and the volume of documents’ manual processing operations
• existence of a uniform framework for data operating at the level of the entire organization
• improving access to critical data by means of the reporting situations
• increasing the efficiency in decisions’ substantiation
• optimizing access at any moment and from any geographic location to the data of interest
• eliminating unauthorized access to information
• increasing the system’s reply speed by archiving the historical data and their availability at any moment
• using a common database by the departments Manufacturing readiness, Production, Commercial, Economic and Mechanical-energetic
• increasing the visibility of information throughout the entire system, while ensuring limited access depending on the users’ responsibilities
• safe, fast and efficient working procedures, so that users can dedicate more time to analysis for decisions’ substantiation
• increasing the coherence and correctness of the data received, processed and sent
• eliminating data redundancy: primary documents (NIR- internal receipt Note, Delivery Note, Consumption Note, Forwarding agent’s notice, Invoice received from supplier, Issued invoice) are entered into the system just once, while the afferent information is transmitted(spread) to all the application’s modules
• control of all the business processes as against the norms (set objectives) is ensured at the operational level) and deviations are signaled
• the budgeting, reporting, financial analysis and costs analysis per activities are managed in timely manner at the analytical level
• at strategic level, the data is aggregated natively and in real time, thus creating support for the strategic management
• significant reduction of the time for drafting the technical documentation (correct and complete management of transfer and operating information)
• real time monitoring of manufacturing costs in order to fall within the allocated terms and budgets, respectively
• improving the information and performance management flows
• image on the client – manufacturer – beneficiary relationship (request for proposal, FIMs, Quality Certificates, RNCs, FRMs and FEM)
• data retrieval and filtering by preset criteria, having direct impact on productivity’s increase
• multidimensional financial-accounting analysis per: type of activity, department, orders
• defining and monitoring the budgets execution , promptness in scheduling and monitoring expenses
• reducing expenses related to documents printing due to using SIVADOC – the documents and workflows management system.

CONCLUSIONS

The integrated information system SIVECO Applications implemented at GRIRO, adjusted to the company specific business requirements, covers all the activity areas and ensures the processes modeling to the end of increasing the entire activity’s efficiency.

The system can be replicated in companies having complex manufacturing activity, as its implementation in a company such as GRIRO represents an important reference in the industry.