The Challenge
An Unsuccessful Competitor ERP Launch
Sapphire Metal Finishing, based in Caldwell, Idaho, faced a significant challenge with their old ERP system. After enduring a two-year-long struggle with an unsuccessful deployment from their incumbent ERP, frustration had reached a breaking point.
Dwayne, the owner, decided to terminate the incumbent ERP’s deployment team and initiated a search for a more reliable solution for their anodizing and powder coating operations. The request for a demo of Steelhead’s plant operating platform designed specifically to manage the ins and outs of the anodizing and powder coating processes, was submitted at 2:00 am and the Steelhead team was reaching out just a few hours later.
The Solution
Swift Deployment with Steelhead’s Plant Operating Platform in 7 Weeks
In their search for a better ERP solution, Dwayne discovered Steelhead through a Google search. Impressed by the website’s content, he grew confident in the support they would receive. Dwayne and his team decided to make the switch.
The deployment with Steelhead, led by Sapphire’s knowledgeable and capable team, was remarkably different. Before the on-site implementation visit, the team had already familiarized themselves with Steelhead, ensuring a smooth and efficient ERP transition. Steelhead's purpose-built system and user-friendly interface significantly contributed to the lightning-fast deployment timeline, completing the transition in just seven weeks.
Sapphire Metal Finishing sought help with:
- Traceability: desired access to order information in a real-time solution would eliminate the mental gymnastics required to memorize and verbally defer tracking processing times.
- Shipping & Receiving: sought a way to eliminate paper and miscommunication issues from receiving parts through to the production floor.
- Updated QMS: previous quality assurance system was “unusable” pushing their interest in a digital system to retire the outdated systems.
The Results
Enhanced Efficiency, Accuracy and Customer Satisfaction
Scanner Line Accuracy & Efficiency: Sapphire Metal Finishing quickly realized the benefits of their new system, particularly in their scanner line operations. Adding QR codes for each tank and precise timing for part processing eliminated guesswork and increased efficiency and accuracy. The scanner line operators found the system easy to use, and the company's reliance on paper-based systems was history, enabling accurate traceability on parts in each tank.
Effortless Reporting: With access to Steelhead Insights, Sapphire Metal Finishing gets access to regular reports and data in the click of a button. “We used to spend 8-10 hours every month creating reports and we love that Insights wipes out this need,” explained Dwayne, the President of Sapphire Metal Finishing.
Order Entry & Power Quoting: The transition to Steelhead's order entry and power quoting functionalities was seamless. Custom inputs and complex equations in power quoting were handled with expertise by Steelhead’s seasoned deployment engineers who played a vital role in fine-tuning the system.
Streamlined QMS & Production Workboards: The workboards, featuring flight bars and racks, highlighted the flexibility of Steelhead's platform, accommodating Sapphire Metal Finishing's unique production processes. Quality management digitized the non-conformance reports (NCRs), Corrective Action Reports (CARs), and return merchandise authorizations (RMAs). The QMS dashboard became a frequently used tool, demonstrating the system’s adaptability to Sapphire Metal Finishing’s needs.
Sensor Dashboard: Steelhead's support extended to maintenance planning with the creation of a customized sensor dashboard for the chemist, who expressed enthusiasm for Steelhead’s sensor capabilities. This contribution to the digital maintenance plan ensured the system met Sapphire Metal Finishing's requirements.
Flexible Solutions: With month-to-month service options, Sapphire Metal Finishing knew that Steelhead was as invested in their growth and success as they were. "I absolutely appreciate Steelhead’s Business Model... It is beautiful,” explained Dwayne. “It is month to month, that shows how much you believe in your product.”
Lightning-Fast Deployment: Compared to the painful competitor deployment, the team was excited to have a fast and painless ERP deployment process. “Five or six weeks, and you are done! You get the entire package, not piecemeal,” explained Dwayne. They can get back to work in record time, armed with a fully digitized plant
Solid Return on Investment: "Every other ERP system we have been introduced to needs a full-time consultant to execute. I am paying an extra $600/month for Steelhead but saving $1500/month in labor. Our Customer Service person quit, and with Steelhead, we do not need to replace her. Steelhead will eliminate 1.5 positions…so it pays for itself (NCRs, reports, invoicing, quoting…all are so much easier)."
Summary
The company, once debilitated by the incumbent ERP with a 22-month deployment, is now thriving with Steelhead’s manufacturing ERP in record time. They are committed to excellence, and they harbor aspirations of Nadcap accreditation in the future. Overall, Sapphire Metal Finishing's experience highlights the transformative power of a purpose-built system, where Steelhead's tailored approach and rapid deployment have turned frustration into efficiency and long-term satisfaction.