Utilizing Odyssey’s Shop Floor Manager module to provide real-time information to Acme’s 115 employees was key to continuing Acme’s Lean improvement process. Appropriate for an ISO 9001:2008 certified manufacturer whose value stream production system was established to control process flow, reduce waste and improve quality, Acme Alliance began the ERP implementation with the Scrap Control, Materials Inventory, Product Inventory, Financial and Shop Floor Manager modules of Odyssey.
Lean manufacturing is all about reducing waste. Using the Shop Floor Manager module, Acme has gained deeper insight into the strengths and weaknesses of various operations and how they are impacting the business. As a result, the company can make quick adjustments that impact the bottom line. For example, Acme now requires employees to report their production against the shop order via Odyssey. Management can review that information in real time to measure production levels.
As part of that process, employees are also required to enter information about the amount of scrap they produce during a specific job, giving management realtime access to accurate scrap reporting and the ability to quickly identify where there is room for improvement in the process. “This gives us the capability to understand if we have internal scrap, where it is, in what quantities, and what we can do to decrease scrap. Closing those points of weakness can impact our bottom line,” says Mike Anderson, Kaizen Promotion Officer.
Acme opted for a phased approach to implementing Odyssey. Initially, the company chose to tackle the basics so it could quickly start reporting on production, manage finances and effectively manage material and product inventory. In the near future, the company plans to implement additional Odyssey features and modules, including the Quality Viewer and Maintenance modules.
“Implementing the Odyssey ERP system gives us the ability to capture and utilize data—including crucial shop floor data—in ways we only used to dream of. I am already impressed with the data we are getting out of the system, and we have only been live a matter of months,” says Anderson. “We are extremely happy with the Odyssey implementation and look forward to growing into more of the Odyssey features in the future.”
“The metalcasting industry is always looking for ways to make better decisions, faster,” states Gacek. “Using Progress OpenEdge allows B&L to grow the Odyssey ERP solution to better serve our metalcasting customers through reliable performance and continuous improvement.”