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| A network
of financial and operations executives have
used techniques they honed while working together
to energize manufacturing operations at a
series of successful startups. The startup
operations this group have been involved in
include Alantec, Assured Access, Sentient,
Shomiti, Sonic Manufacturing, ipVerse, Alidian
and Desana Systems. Each of these companies
has successfully made the transition from
product development to manufacturing and a
number were sold to major industry players
such as Cisco and Alcatel. The manufacturing
operations of all these companies have been
run by a small core of individuals that have
worked together and developed, through experience,
a methodology for jump-starting manufacturing
operations from zero. One of the keys to their
success has been the development of simple
and flexible information systems that allow
them to keep a close touch on operations without
requiring extensive investment or support,
according to Rich Weber, Director of Marketing
for Desana Systems, who has been a member
of this informal group from its earliest days.
Two of the three core members of this group,
Weber and Al Sadler, first worked together
at Omnitel in the late 1980s. They left
Omnitel towards the end of the decade to
join a networking startup called Alantec,
where they met up with the third member
of the team, Pat Royan. In the early days
of Alantec, one of the key challenges the
group faced in starting up manufacturing
operations was implementing an ERP system.
"We were extremely limited on both
financial and human resources," said
Royan, who served as chief financial officer
of Alantec. "We needed an inexpensive
system that could be implemented quickly
without any customization. But we also needed
fully integrated MRP (material requirements
planning), inventory, order entry and financials.
As fast as we expected to grow and as fast
as inventory depreciates in a technology
business, we recognized that the ability
to generate real-time reports on our inventory,
cost of goods sold and financial performance
would be critical to our success."
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"We looked at tier-one ERP systems
such as SAP and Oracle," Royan continued.
"They could handle our business with
ease but the minimum cost and lead-time
to get them up and running was $1,000,000
and one year. We couldn't handle either
number. So we looked at PC-based systems
and discovered they had good financials
and in many cases job costing but they lacked
high-end integrated MRP. MRP is essential
to integrate order processing, inventory
and cost of sales in a way that allows management
to keep a pulse on what's happening in a
business. Then we discovered Expandable
Software. The neat thing about this package
is that it's still the only one I know of
that provides full-fledged and integrated
MRP in a simple PC framework that allows
it to be implemented in a few weeks. And,
the system's low cost is well-suited to
startup organizations."
The implementation worked out perfectly
and played a major role in the success of
the startup. "We got the system up
and running in just a few weeks without
having to get a consultant involved,"
remarked Weber, who served as Information
Systems Manager for Assured Access. "One
factor in our success was the ability of
the software developer to provide experienced,
in-house trainers, eliminating the need
to contract consultants. Getting a fully
integrated ERP system up and running as
quickly as we did provided a major boost
to our organization. We had the ability
to track, at any given instant, exactly
what inventory we have in stock and how
much would be required to meet our manufacturing
plans. We could also make profit and cash
flow projections on a real-time basis in
virtually no time, simply by using the information
already entered into the system for manufacturing
scheduling. The whole thing ran like a top
and required only a single person to support."
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Weber said that in addition to simply
selecting a software package, the Alantec
team developed a core of business practices
that played a major role in the success
of that firm as well as others yet to come.
"We came together as a group and decided
we would enter all significant information
into Expandable," Weber said. "Our
philosophy was that if it wasn't in Expandable
then it didn't happen. This meant that we
soon developed an information storehouse
that we could use to monitor every aspect
of the business. All of the members of the
management team saved considerable amounts
of time because, instead of walking across
the plant to find out the status of a work
order, for example, we could simply call
it up on the screen. Of course, the users
of first-tier ERP systems such as Oracle
and SAP enjoy these same advantages. The
catch is that to obtain them, the company
would need to invest millions, develop a
team of people to support them, and go through
a long implementation process. We achieved
essentially the same benefits for a small
fraction of the price, were able to complete
the implementation in a few weeks, and haven't
needed any dedicated support people."
Alantec went on to become a leading supplier
of multi-service networking solutions and
is widely recognized as the company that
commercialized ATM technology. In 1996,
Fore Systems acquired the company for more
than $600 million and has continued to expand
its product line. The success of this implementation
became common knowledge in Silicon Valley's
startup community and was one of the reasons
that Weber and Royan were asked to join
a new startup, Assured Access, even before
the merger became final. "From the
beginning, we didn't have any doubt what
type of ERP system we were going to install,"
Weber said. "In fact, if my memory
serves me correctly, our second purchase
order was to Expandable for the software.
That was after we bought computers but before
we bought our furniture." Several other
people in the operations team at Alantec
joined other startups after the company
was purchased. Dan Creager, Mike Park and
David Leonard joined Shomiti and Dave Ginsberg
went with Sentient. Both of these companies
also implemented Expandable. Sentient was
purchased by Cisco Systems in 1999 for an
undisclosed price and Ginsberg soon joined
Sonic Manufacturing, where he also led an
Expandable implementation.
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Assured Access's business was producing
a family of multi-service access concentrators
for Internet Service Providers (ISPs). "Since
we were already familiar with the software,
it literally took us hours to get up and
running at Assured Access," Weber said.
"We created the chart of accounts in
an Excel spreadsheet and downloaded it into
Expandable and we were in business. Not
a bit of consulting or customization was
required." Royan said that the integration
between MRP, inventory, order entry, purchasing,
and financials was crucial to Assured Access'
success. "Consider the importance of
inventory in the networking business,"
Royan said. "Every year our selling
prices drop by 20% to 50%, which means the
value of our inventory is dropping by the
same amount. Expandable provides powerful
tools for keeping inventory as low as possible
without incurring stock-outs that reduce
our sales. The software's sophisticated
MRP capabilities immediately explode every
order we receive into the components required
to produce it. The fact that MRP is integrated
with inventory and financials means that
we know in real-time exactly where we are.
To make sure we stay on track, we dispensed
with physical inventories but employed a
full-time stock person who performed cycle
counts on a daily basis. The system helped
us successfully navigate the perils of a
networking startup." The bottom line
is that the company successfully got its
manufacturing operations off the ground
and was sold to Alcatel in 1999 for $350
million.
In a process that Weber compares to the
spreading of a virus, the team at Assured
Access soon joined three more startups.
Pat Royan became Chief Executive Officer
and Rich Weber became Marketing Manager
at Desana Systems, a company that is developing
next-generation service delivery from the
data center. Art Klein became CEO at ipVerse,
a developer of open, intelligent network
operating systems for integrated voice and
data communications services, where he hired
Dave Leonard from Shomiti as Vice President
of Finance. Al Sadler became Vice President
of Operations at Alidian, a company that
delivers optical service network solutions
for metropolitan area networks. As you might
expect, each of these companies became Expandable
users. In the meantime, PCB Assembly, a
supplier to Assured Access, implemented
Expandable based on their recommendation
and subsequently sold their company to Flextronics.
Weber said a key reason that members of
the network have continued to work with
Expandable over the years is that the software
has been continually improved to keep up
with their growing needs. "Expandable's
integration with the Agile product data
management system was very useful in integrating
our engineering and manufacturing operations
at Desana," Weber said. "When
an engineer makes a change, it goes through
an approval process that is controlled within
Agile. As soon as the change is approved,
it instantly updates the Expandable bill
of materials. We can easily run an impact
report to determine how the change affects
our inventory and manufacturing schedules."
Royan concluded: "Expandable has played
a significant role in the success of every
startup that I have been involved in. It's
the only ERP system I know that's simple
to install and use, yet provides industrial
strength MRP and scales to over $100 million
in sales without difficulty."
For more information contact Expandable
Software, Inc., 1171 Homestead Rd., Santa
Clara, CA 95050. Phone: 408-261-7880. Fax:
408-247-2160. Web: www.expandable.com. Email:
sales@expandable.com.
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