A member of the BCA Group, BCA Leisure was founded in 1981 and specializes in manufacturing electrical systems and electronics for the caravan and motorhome industry. Its client base of major caravan manufacturers includes Bailey Caravans, Lunar, Coachman, Elddis and Adria.
BCA Group has an ongoing program of inward investment and the Syspro system is part of this, representing as much as 5% of the company’s turnover and ensuring it has the capabilities needed to meet the ever-changing requirements of caravan manufacturers.
Several areas of the business have benefitted substantially from the implementation. Works Orders, for example, contain all the details for each job, including Bill of Materials, time needed for the job, the production team assignment, and the shipping date. BCA also uses Syspro to provide a preliminary Dispatch List, which gives the production teams an overview of all jobs and their due delivery dates.
The company uses the MRP module to look at the component demand for each job in detail. From this, data is extracted to produce a spreadsheet which allows staff to analyze orders, material demands, stock levels, and the average number of weeks to maintain production. This detailed study prevents outages caused by a lack of components.
With Syspro, BCA has reduced stocktaking time by up to three days across its three warehouses. New accuracy levels enabled the management team to quickly review any discrepancies, and the stocktake was within 0.5% of expectations. Syspro’s Work in Progress functionality added to the precision of the stocktake by providing an accurate picture of stock items.
The BCA Group uses Syspro’s MRA functionality, which covers the end-to-end process, for warranty work. Customers can report an issue to the Customer Service Department and it is immediately logged into the system. Invoices, dispatch notes and credit notes relating to the warranty query are automatically produced. This improvement in dealing with warranty issues has freed up time for more strategic tasks and enabled a faster response to customers.
Syspro’s real-time reporting provides the BCA Group management team with a live, accurate view of the business. Instant access to data such as the value of jobs and profit margins, forward-booked orders and component levels ensure the ability to quickly react to current and future demands. It also helps BCA to handle short turnaround times for orders and ensures there are adequate raw materials available for completing work to schedule.
BCA Group needed to replace outdated systems with an integrated solution capable of meeting its particular requirements. The objective was to implement a system that would integrate accounts, manufacturing and distribution.
After a thorough market evaluation, BCA Group selected a fully integrated Syspro ERP system to assist with simplifying its complex manufacturing processes. The Syspro solution helps manage the entire process from customer order through to manufacturing, final delivery of the finished products, invoicing and payment collection.
