Overview

Introduction

The foundry industry supports the world’s manufacturing needs in automotive, aerospace, construction, heavy equipment, and other industries. They are the key point of manufacturing, but these foundries sometimes face challenges such as volatility in planning, scheduling, and metallurgical challenges in high-volume production environments. Emergys tackle these challenges through its SAP Qualified Partner Packaged Solution (QPPS), known as SAP FoundrySmart – SAP Certified Foundry Solution.

It combines SAP Business Suite core modules with best-in-class enhancements to deliver real-time information, planning, and traceability which results in increased operational control, cost awareness, and productivity on the Shop-Floor that traditional systems are unable to deliver.

Why FoundrySmart Is Important for New Edge Manufacturers?

Casting Manufacturers need foundry solutions that enable faster decision-making and improved material efficiency. Also, applied foundry solutions streamline and optimize end-to-end foundry operations, from raw material planning to final casting output. They enable data-driven decision-making, improving process efficiency, quality consistency, and overall productivity across the foundry. FoundrySmart meets this need by using SAP Business Suite modules and adding casting-specific processes with innovations. This SAP foundry solution is scalable and allows for growth while offering the visibility and control necessary to succeed in challenging markets.

SAP Business Suite Solutions

The sap foundry solutions rest on SAP’s business suite for seamless ERP (Enterprise Resource Planning):

  • Finance: It involves the management of assets, payment, cost, and accounts to have an appropriate understanding of profits and to manage the expenditure.
  • Sales: It effectively manages the price, payment, and customer transactions to have the appropriate efficacy of sales.
  • Procurement: It manages suppliers and contracts to connect contracts.
  • Manufacturing: It helps in planning and managing production, materials, and quality to improve visibility.
  • Supply Chain: It tracks inventory, warehouses, and products to prevent oversupply and undersupply.
  • Services Management: Assistance is provided to ensure customer satisfaction through after-sales services.

Manufacturers can easily implement this SAP foundry solution by utilizing pre-configured packages that integrate core Business Suite modules with foundry-specific enhancements. They can achieve full traceability from the melting bay to final casting, optimize furnace charge mixes to reduce costs, streamline daily scheduling to eliminate bottlenecks, and gain real-time visibility through SAC Analytics dashboards.

How FoundrySmart Stands Out with its Foundry-Specific Enhancements?

Based on recent Market Research, the foundry industry ranks as the second-largest casting production base in the world, contributing 12 million tons per annum. It is also estimated that the industry will rise to 42.5 billion USD by 2029, growing at a CAGR of 9.4 percent from its current value of 23.6 billion USD. It also supports the automotive, engineering, infrastructure, and export industries and comprises 4,500 small and medium-sized foundries, which employ more than 500,000 people directly.

With a clean SAP core for future scalability, metal casting and mining manufacturers can reduce waste, improve on-time delivery, optimize inventory levels, and drive faster ROI by leveraging rapid 4–6 month deployment timelines, automated defect analysis, and seamless integration across finance, sales, procurement, manufacturing, and supply chain operations.

  1. Real-Time Planning and Scheduling: Ensures on-time delivery and prevents bottlenecks by managing production flow with custom dashboards.
  2. Charge Mix Optimizer: Compares furnace recipes using current costs and target yields.
  3. Cost and Yield Analysis: Monitors melt efficiency, batch performance, and rejection trends using SAC Analytics Cloud.
  4. Pattern and Metallurgy Tracking: Manages tooling life cycle and connects batches, returns, and defects for quality control.
  5. Platform Aligned with SAP: Supports the deployment of SAP Business Suite, SAP Cloud ERP, and SAP BTP.
  6. Traceability: Enables complete tracking of every production batch across the supply chain.
  7. O2C Cycle: Provides end-to-end visibility and management of the order-to-cash process from order receipt to fulfillment.

Challenges Resolved with SAP FoundrySmart Solution

It resolves various challenges faced by a company directly which include:

  • Allocation of sales orders regarding inefficiencies disappears
  • Balancing and planning gaps regarding production lines are resolved directly
  • Delays regarding WIP monitoring are resolved directly
  • Reduces inventory management issues
  • Delays regarding rejection and on-time delivery are resolved directly
  • Pattern lifecycle issues receive direct solutions

This provides a complete process of visibility for businesses. It helps them run data-driven operations smoothly. It helps them improve operations, reduce costs, and deliver quality products on a large scale.

SAP-Qualified Partner Packaged Solution Powered by Emergys

Emergys is an SAP Gold Partner and a trusted solution provider for the foundry industry. With over 2 decades of experience in the industry, we help our clients transform their business.

As an SAP Gold partner and a PCOE Partner, we deliver this solution which is built on top of the SAP Business Suite. We help our clients overcome the challenges faced with production planning, work-in-progress tracking, and cost traceability.

Conclusion

The castings market for metals has seen increasing demand, especially in terms of growth rate, due to increasing infrastructure development, changing transportation requirements, and growth in industries. In this market, foundries that implement smart technology have a significant advantage.

This ready-to-deploy solution enables foundries to have control, real-time information, and efficiency, thus helping them grow in a sustainable manner and stay ahead of the curve. The next step in your journey towards smarter, future-ready foundry operations with us. Leverage the power of smart technology with FoundrySmart.

Frequently Asked Questions

SAP FoundrySmart is an SAP Qualified Partner Packaged Solution (QPPS) developed by Emergys. It integrates core SAP modules with foundry-specific enhancements. It allows foundries to achieve better efficiency and productivity in their factory operations by cutting down costs, effective production planning, and better traceability through real-time visibility.

The SAP FoundrySmart solution has been developed for fast implementation using pre-configured modules. It can be successfully installed by most companies within four to six months.

SAP FoundrySmart helps organizations face major issues within the industry, including poor production planning, inadequate Work in Process (WIP) management, stock imbalance, late defect detection, and lack of traceability. It assists them to make better decisions and save costs by giving them full visibility into their processes and operations.

The role of foundrysmart in melting bay workflows is that it enhances melting bay efficiency with real-time monitoring, optimized charge mix control, and standardized workflows, ensuring consistent output and reduced process variability.

  • Real-Time Planning and Scheduling
  • Charge Mix Optimizer
  • Cost And Yield Analysis
  • Pattern And Metallurgy Tracking
  • SAP-Aligned Platform
  • Traceability
  • O2C Cycle

To see FoundrySmart in action, access our detailed demo video. It provides a comprehensive overview of key features, workflows, and business benefits.

View the Demo Video

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