Building a Valve Management Powerhouse: A Custom VSM for Kirloskar Group
Zelite Solutions developed a custom Java and Oracle-based Valve Schedule Management System (VSM) for a Kirloskar Group manufacturer, streamlining valve selection, quantity estimation, and material procurement, replacing error-prone manual processes and improving efficiency.
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In today's competitive manufacturing landscape, optimizing component selection and procurement processes is crucial for cost-effectiveness and project success. This case study explores how Zelite Solutions designed and developed a custom Valve Schedule Management System (VSM) for a leading company within the Kirloskar Group. This innovative solution empowers the design team to streamline valve selection, material estimation, and procurement workflows.
Our client, a prominent manufacturer within the Kirloskar Group, provides a diverse range of products in compressed air, air conditioning, refrigeration, and hydraulic power transmission solutions. Their design division grappled with the following challenges in managing valve schedules:
- Error-Prone Calculations: Manual calculations for valve quantities and specifications based on piping class were time-consuming and prone to errors.
- Inefficient Workflows: Paper-based processes and spreadsheets hindered communication and collaboration between design and procurement teams.
- Material Procurement Delays: Inaccurate estimations often led to delays in material procurement and project execution.
Zelite Solutions delivered a comprehensive VSM application built with Java technology and using an Oracle 10g database. This secure, web-based system boasts five key modules:
- Admin: Centralized user management and system configuration functionalities.
- PMS (Piping Materials Specification): Standardized specifications for valves and related components based on piping class.
- Projects: Easy project creation, allocation, and tracking functionalities.
- Valve Schedule: Intuitive interface for inputting project details like lines, equipment, and hook-ups. The system generates valve quantities and specifications based on standardized formulas and user-defined project parameters.
- Reports: Comprehensive reports summarizing valve types, quantities, specifications, and project details.
- Single Sign-On (SSO): Secure user access and authentication for a seamless login experience.
- Automated Calculations: Eliminates errors and streamlines valve quantity and specification determination.
- Integration with Oracle ERP: Seamless transfer of material requirements directly to the Oracle ERP system, automating material procurement workflows.
- Improved Project Management: Enhanced project allocation and tracking capabilities facilitate efficient project execution.
- Reduced Business Losses: Accurate material estimation minimizes over-procurement and associated project delays.
The custom VSM has significantly improved the client’s valve schedule management processes:
- Enhanced Accuracy: Automated calculations and standardized specifications ensure accurate valve selection and procurement.
- Increased Efficiency: Streamlined workflows and ERP integration expedite material procurement and project execution.
- Reduced Costs: Eliminating manual calculations and minimizing over-procurement leads to cost savings.
- Improved Communication: A centralized system facilitates better communication and collaboration between design and procurement teams.
This case study demonstrates the value of custom software solutions in addressing specific industry challenges. Zelite Solutions' VSM empowered the Kirloskar Group company to achieve increased efficiency, accuracy, and cost savings within their valve schedule management processes.
