This case study explores the manufacturing ERP deployment experience of Franke Plating Works, a plating company based in Fort Wayne, Indiana, to Steelhead Technologies. The deployment involved 30 plating operators across two plating lines. The study highlights the positive impact on operations, customer satisfaction, and financial insights achieved through the implementation of the job shop software.
The Challenge
Before Steelhead, Franke Plating Works required a lot of manual communication and paper to track information. These redundant tasks wasted valuable time in the shop and routing information. For example, to add an expedite fee, they would write it on the work order traveler and communicate to the production floor verbally.
For one customer, the invoicing representative would hand-calculate the invoice total based on the information on the shipper, trusting the information listed was accurate with very little visibility. Job costing was also an area of confusion as they did not know how much time or money they were spending to run a job.
Instead of cloud-based technology leveraging the internet, the team relied on “sneaker net,” a term used to refer to physically running around on the production floor or to offices to deliver sensitive information.
“I used to have to walk down the street to visit Rachel [accounting representative two blocks down the road] to hand her my signed Purchase Order,” explained Julius, the Laboratory Manager. “She would then re-create it in a new format and send it to me to send to the customer.”
The Solution
In deploying Steelhead’s job shop software, all charges and communications are automated and streamlined. No more writing information on paper, running out to the shop floor to communicate orders, or hand-calculating invoices based on shipper details. With Steelhead’s job costing data and auto margins, they are no longer in the dark on how much each job is costing them to ensure profitability.
The Results
Smooth Transition and Job Costing Accuracy: This deployment featured two zinc plating lines with hanging timers and red line timers for accurate job-costing including labor costs and operational costs. The company expressed satisfaction with the platform, acknowledging it as a valuable asset in achieving its goals.
“I can go to one place and find everything in one centralized location,” explained Jamarcus Everette. “Before, we would print off a piece of paper and it would get lost. In Steelhead, quotes and everything along with it sync up where I can find it. We don’t have to put extra information in the logs.”
Efficient Transition Period: The manufacturing ERP deployment at Franke Plating Works was efficiently executed, with the plating company completing the transition within just one month. The positive reception from the operators and the management team further emphasized the success and speed of the deployment.
Operational Improvements: Steelhead facilitated meticulous and time-consuming tasks managing the plating process, such as quoting and work order management. Operations were streamlined through power quoting and efficient order linking. The system's ability to auto-update pricing and eliminate back-and-forth communication streamlined operations and improved accuracy.
Invoicing Insights and Efficiency: Steelhead’s manufacturing ERP uncovered discrepancies in invoicing practices that were previously data-entry heavy. This led to a correction that potentially saved the company significant revenue.
Enhanced Visibility and Data Collection: The system's capabilities in collecting and displaying data, such as rack time and red line timers, impressed the management team. The added visibility empowers decision-makers to make informed choices based on real-time data.
"Steelhead has been helping a lot,” explains Jamarcus Everette, Manager. “The visibility holds our Operators accountable. ‘You stepped it’ or ‘you didn’t step it; you left it sitting in the red line timer for 14 hours’... it’s all available in Steelhead.”
Inventory Management and Procurement Optimization: Franke Plating Works experienced a significant improvement in inventory management as they transitioned from manual purchase order creation to an automated process, reducing the time and effort involved in procurement.
Maintenance and Operational Efficiency: Building out maintenance checklists, startup and shutdown procedures, and sensor dashboards demonstrated the system's versatility. The implementation of these features significantly improved overall operational efficiency.
Steelhead Technologies’ manufacturing ERP had a tremendous impact on the plating operation’s digital transformation. From efficient digital workflows to financial insights and enhanced operational visibility, the company experienced comprehensive benefits of embracing modern technology. Their success story serves as inspiration for other companies considering similar digital transformations to optimize their operations.
Thank you to the team at Franke Plating Works for allowing us to grow with you!
Transforming Plating Operations at Franke Plating Works
The team together on deployment day to celebrate the launch of their new paperless production system.