Case study: rubber goods manufacturing software implementation

READ KAROL'S STORY TO LEARN MORE

Rubber goods manufacturing software implementation – taming chaos

Read the story of one of our clients from rubber goodsnand elastomers industry.

“Before we implemented Prodio we’d had many problems such as not knowing which percentage of the given order was completed or how many elements need to be produced to finalize the projects” – remembers Karol Wikło the owner of WIGUM company. “We didn’t have any control over the norms or many of the details used for proper pricing. We also didn’t know how many elements produced a particular employee in the scale of the calendar month.”

 

This was also the reason why many operators mixed up raw materials, not benefiting from the clear information flow, because the manager couldn’t be present at the production hall all the time to delegate and explain tasks. It was tiring: never ending questions about how to do something, what are we doing, what are we going to produce tomorrow, what is going to be the next order, etc. An absolute nightmare.

It was very frustrating not to be able to answer simple questions, ex. when the customer phoned to enquire about the progress on the order to learn the final date or check on the deadline the answer was “created” on spot without checking in the system.

That’s how the decision to start changes was made, because there was no other way to tame the chaos that was progressing with each new order. “There were more and more new customers, but this instead of making me happy, dragged me down” – remembers Karol. “I was depressed and unable to plan what is going to be produced, it was impossible to schedule orders  and give customers clear information on deadlines. We felt constantly overwhelmed” – he adds sadly.

What happened in WIGUM after rubber goods manufacturing software implementation

First thing which really impressed us was the check in/check out system, where everybody uses a personalized card to start and finish their day at work as well as progress with their tasks, operations and orders. Thanks to this system there is a clear working time history, which can be download and saved at any time. “It is an amazing functionality,  because you know straight away how much time people spent working; you can’t skip it or omit” –  the owner adds happily.

czas pracy elastomery wdrożenie

Another impressive feature is the fact that thanks to card system, it is possible to see who is working directly on your smartphone or tablet. “I can stay at home and I am still able to check if my operators are at work, which tasks are they working at, what’s the progress. It is superb!” – comments Karol.

rubber goods manufacturing software implementation

Regarding employees themselves it is a very practical solution. There are always some operators in the company who can’t remember how to make a particular detail or what is the correct production process. Now they don’t have to rely on the memory, but rather take the advantage of Prodio, where all information is collected and saved.

elastomers implemetation production software

When the operator starts to work on the order and he is not sure of some details of the process, he simply checks with a few clicks to retrieve necessary information stored in Prodio. If they follow step by step production procedure according to tips from the software it is impossible to make a mistake. Thanks to this a company can achieve repetitiveness. elastomery wdrożenia

All details start to look the same, because the whole  process is identical and follows the same routine. The defects are minimized, especially those resulting from using incorrect raw material, because the production is standardized. This in turn helps to achieve higher transparency and clarity. The workers know what is happening at the production hall, there is a plan what is going to be produced this, next or the following week. They are able to see work planned on machines, the time needed for completion of the particular order and all important elements of the master production schedule. They get simple information whether the machine is occupied, in service or they can use it to complete the task.  

“Judging by the number of orders entered to Prodio we make a joint decision, together with the whole team whether we work overtime or have some extra hours on Saturdays, because it is perfectly clear in the system if it is necessary” – says the owner. 

The benefits of Prodio are visible for everybody. “I honestly think that they are happy to use it” – adds Karol.

“My private life has also changed. Maybe I haven’t noticed it straight away, but I know I gained confidence and certainty. There are many questions which I can answer now working from home, just by logging into Prodio from my smartphone. I can check for the piece of mind ex. what happens at 7 pm in the production hall. Obviously there are cameras and monitoring system, but now I am able to see which detail is being produced, by whom and how long it takes. It offers me a sense of security. I know that when you are on holiday you are supposed to rest and not think about your business (…) the same when I am away on business trip; but being a small manufacturer it is hard to neglect your business; sometimes it is enough to take a sneak peak at what’s happening at the production hall and you can go back to your things” – tells the owner.

program do zarządzania produkcją

If you want to introduce organization at your production hall, to have all production processes standardized and control over what is going on in your workshop, try to use Prodio. There will be no more trivial questions about production times, operations, processes. 

wdrożenia prodio elastomery 

It is an investment worth making. You will impress your clients or auditors when you show them how smooth things are. This is a kind of  “wow” effect. It proves that even a small company can be organized and modernized and the budget isn’t an issue.

If you want to read more about how to use Prodio in elastomer goods industry click HERE.

production planning trial

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