Computerised production system reduces stocks

Plastics processor has implemented a computerised production control system in just three months - resulting in reduced stocks of high value raw materials and improved profitability.

Plastics processor Poly Hi Solidur has implemented K3 Business Technology Group's JobBOSS computerised production control system and Sigma accounts in just three months.

This has resulted in major benefits such as reduced stocks of high value raw materials, increased visibility of all company activities and improved financial accounting and profitability.

Financial Controller Paul Smalley joined the company in 2004 and one of his first tasks was to replace the company's existing production control package.

"We short-listed packages from K3 Business Technology Group, Exel, Pumasoft, Sanderson and McGuffie Brunton before selecting K3's JobBOSS system and integrated Sigma accounts to replace a DOS-based Pegasus system.

Our German and US companies run SAP systems but gave us a free choice in system selection, and JobBOSS accommodates a link to the SAP systems which we use for purchasing materials.

We first saw JobBOSS in an iTSHOWCASE magazine article and it appealed to us because, unlike many systems on the market, it supports our manufacturing and distribution activities rather than one or the other.

It is also Microsoft approved and keenly priced on a modular basis and, as we mainly needed basic scheduling rather than full MRP, was ideal for us.

JobBOSS's lot-tracking and traceability module was also critical for the medical side of our business." K3 consultant David Lloyd and Paul Smalley's team held a one-day planning meeting to decide on details such as training needs, data transfer requirements and the order of module implementation.

After a two-day generic training course by three project managers from finance, sales and production, plus some shorter user training sessions and sample data entry pilots, the system went live in December, 2004 - in real time just three months from signing the contract.

"We have gained some major benefits from the changeover," adds Smalley.

"Management decisions are now supported by live, accurate information available in minutes from Crystal Reports.

Previously it either was not available or we had to key in parameters, manipulate data and format it in Excel.

This took too long and was not reactive enough for effective business decisions.

In the finance area, Crystal Reports is very flexible and can be integrated between any accounts system - in our case Sigma.

PHS is also reaping many solid benefits just by changing over from DOS to Windows technology.

Windows is user-friendly and easy to navigate with the mouse, and there are many familiar Windows features that users find very helpful.

There is also a variety of data search, printing, cut and paste and email functions that were not available with DOS.

Even the basic 'favourites' enable users to encompass their own work patterns and workflow.

"JobBOSS has given us much greater visibilty of all activities throughout the company," says Smalley.

"We now have accurate job status information and realistic promise dates on shop loading because the JobBOSS scheduling traffic light facility highlights the overloads and bottlenecks.

Labour and material reporting is also very comprehensive and helps to refine our costing model which gives us a clear picture of the profitability of each job.".

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