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Bry-Air Finds the Right Environment to make its Delivery Promises and Cut Overheads
May 2006

Bry-AirBry-Air is known worldwide for its expertise as a "solutions" company for moisture and humidity control for general industry as well as reliable auxiliary equipment for plastics processing. Operating within a broad framework of "Environment and Energy", Bry-Air today is a multi-product, multi-location company with plant locations in India, Malaysia and affiliate plants in USA and Brazil. 

Bry-Air (Asia) Pvt. Ltd, part of Pahwa Enterprises, specializes in the manufacture of Desiccant Dehumidifiers and Plastics Auxiliaries and is the only dehumidification and plastics auxiliary manufacturer in the world with ISO 9001: 2000 as well as ISO 14001: 1996 certification. Their range of products include Desiccant Dehumidifiers (Honeycomb and Granular type), Wood Dryers, Seed Dryers and Storage Systems, Flexible Barrier Storage Systems and Plastic Dryers & Auxiliary equipment and Air and Gas Purification Systems.

They have three state-of-the-art manufacturing facilities with CNC Turret Punch Press, CNC Press Brake, and Powder Coating Equipment etc. supported by CAD, Computer Aided Engineering, government recognized Environmental R&D lab and about 150 highly skilled personnel. They are located near Delhi, India, in the industrial area of Udyog Vihar, Gurgaon, Haryana.  The products are sold not only in the Indian Market but also exported to over 40 countries in South East-Asia, China, the CIS countries, West Asia, Middle East, Africa, S. Africa, Australia and to Bry-Air Inc. USA.

Bry-AirThe Problem
Before Preactor was implemented all planning was carried out manually but as production volumes were increasing they found it difficult to meet their delivery commitments.  The products had deep Bills of Material and some required bought out items that had long lead times.  The Planning Department did not know when a particular assembly would start in order to plan the manufacture of the parts for the assemblies to use.

Some of the items are critical both in terms of functionality and cost but synchronizing their procurement with when they were really needed was not possible without a more robust and accurate planning system.  Hence inventory levels and stock holding costs were much higher than they would have liked.

Planning for the other resources, which included skilled and semi skilled operators was also a real challenge.  A mixture of different products requiring Make to Order, Make to Stock, Assemble to Order and Engineer to Order scenario, added to the complexity and required a ‘mixed mode’ approach.  The Planning Department had to make sure that the orders were planned to be completed within due dates and yet utilize resources as effectively as possible.  Utilization of critical resources such as CNC machines (which give a high output), Fabrication stations and Assembly stations (where highly skilled operators are required) constitute an important part of the planning process.

Bry-AirThe Solution
Bry-Air had evaluated a few scheduling software solutions before choosing Preactor APS with its PBX option, to meet their planning and scheduling needs. As ERP was not available at the beginning the PBX is used to hold the BOM information and for Bill of material explosion to creating the work orders.

Preactor was configured to sequence and schedule orders taking into account both machines and skilled personnel planning.  Currently the skilled personnel planning has been done at the macro level, but this will be enhanced later to assign work to individual staff with the required skills.

Preactor was implemented in November 2004 and has been working as a stand-alone system.  Bry-Air has gone for implementation of an ERP system from SSA LN (formerly known as Baan ERP), Preactor has been integrated with Bry-Air ERP system prior to going live on 1st November 2005.

The detailed Order information along with Exploded Bill of Material information is now imported from the LN into Preactor which holds information on workcentres, machines, skilled workers and other constraints as well as calendars and shift patterns.

The Schedule is generated in Preactor and the start time, end time, along with the individual resource selected for each operation exported back to LN. The Planning Department releases the weekly schedule to the shop floor.  Feedback on operation progress is updated daily to the Master scheduling system.

The Benefits
The Planning Department monitors schedule adherence of every department and has graded them as A, B, C, or D.  This has had a marked effect on the discipline level which is an essential element of obtaining the full benefits of an advanced planning and scheduling system. 

Deepak PahwaThese benefits have included improved productivity, reduced inventory levels and improved delivery performance.  In addition Bry-Air is now able to effectively plan for the time of the skilled operators which has reduced the amount of overtime required.  This consequent cut in overhead and operational costs has been a major part of Bry-Air’s fast return on its investment in Preactor.

Mr. Deepak Pahwa, CMD of Bry-Air Asia Pvt Ltd., the driving force behind this project, is very happy with the results obtained from Preactor.  He is well known for his deep knowledge of manufacturing systems, scheduling and ERP, and decided to invest first into scheduling and then ERP because of the fast implementation time and ROI that was available with APS systems.  His previous experience and now with the success of Preactor at Gurgaon has convinced him that other manufacturing organizations should also follow this route, implementation of scheduling first and then ERP. And he is following his own recommendations with the roll-out of Preactor to his other Pahwa Group companies.