Treko Laser specializes in production for the automotive and machinery industries. The company was looking for a solution to help organize its production process. The firm decided to move away from production management based on production cards and supervision based on Excel and Access databases, as well as a proprietary finance solution. Increased production and a growing number of orders led to an inefficient information flow system. Tracking individual production orders was very difficult. The company had problems assessing the actual demand for materials and estimating the time required for the “collision-free” execution of orders. Because Treko Laser carries out various, often non-standard orders, frequently in very short series, it is forced to maintain a wide range of material grades with different properties and applications in its warehouses. Between 150 and 250 tons of materials pass through the company’s warehouses monthly. To ensure uninterrupted operation, stocks must be maintained at a level of 300-400 tons.
– At some point, paper was no longer enough to ensure supervision over production continuity. The most critical element of the process was information about work-in-progress. When deciding to purchase an ERP system in 2005, we wanted to capture all essential elements of the cycle: material receipt, warehousing, technology development, conducting and identifying work-in-progress, assembly, and shipment to the customer. At that stage of development, we were still a small company employing about 35 people – says Marek Wodnicki, Technical Director at Treko Laser Sp. z o.o.
The process of selecting a new system that met Treko Laser’s expectations lasted 4 months. During the analysis of offers, the company checked the software for production functionality and compatibility with numerically controlled devices. Thanks to the contract with Macrologic and the implementation of the Xpertis system, the management of Treko Laser was able to introduce the digitization of the entire production process from the offer through the order, work order, planning, and execution, up to warehouse receipt and sales to the customer. This solved data transfer problems and allowed for the tracking of every order. The detail of the process was brought down to the level of a single machine. This allowed for precisely determining the stage at which an order is located and identifying the location of a specific element on the production floor. This is important due to the simultaneous execution of several operations in the production line and the frequent execution of individual orders. Thanks to such precise information, the company can now conduct accurate productivity analyses. Each employee was equipped with an individual numerical code used to start the execution of an order. The system therefore records the completion of an operation with an accuracy of one piece, the time and date of execution, and allows for the identification of the operator, machine, and material certificate. Accurate information allows the management to conduct precise performance analyses. In the case of complaints, it is easy to determine the circumstances under which an error could have occurred, and as a result, prevent the causes of defects in the future and improve the production process. Additionally, full support for the production process enabled precise quality control – both planned and random inspections. It is possible to generate inspection reports, which are saved and stored in the system. Planning and detailed production control also facilitated the work of planners. They can now precisely decree which order is to be executed on which machine and when. This is possible thanks to the control of machine man-hour loads on individual days/shifts. As a result, the load on the machine park and shift work is optimized. A consequence of better production order planning is easier supply planning. The Logistics Department receives a clear list of all orders and the quantitative and qualitative demand for sheet metal. Efficient information flow allowed, despite the growing number of orders, for the stabilization of inventory levels. The introduction of logistics planning improved supervision over the timeliness of elements commissioned for cooperation. The person supervising logistics gained the ability to instantly check which products are still being manufactured by individual subcontractors. The use of electronic document flow throughout the production cycle enabled the introduction of certificate handling. All registered raw material parameters are automatically transferred through production until the finished product is released. The Xpertis system also enabled the handling of bulk operations. This was achieved using built-in terminals in laser machines or press brakes, which were connected to Xpertis Logistics program terminals. This solution reduced Treko Laser’s costs associated with purchasing additional data processing computers.