Case Studies
Replacing Paper Documentation With Custom Manufacturing Execution System
Improving a $2.6B Packaging Process Through Custom Application Development
Client’s Challenge
Manual, Outdated Processes
Reliance on paper documentation and manual quality-control checks slowed shipping and risked product quality standards.
Our Solution
Software Development & Process Automation
Build a custom application to move their manufacturing teams to digitized documents and forms and an automated quality-control process.
Value Realized
Increased Satisfaction & Cost Savings
Our work helped this client eliminate reliance on paper documents and forms, reduce man-hours, and increase product integrity.
Project Details
Our client was using a paper process to document its heavily regulated manufacturing process. Annually, the existing workflow required 6,000 hours of manual review to determine product acceptance for the shipping release of 820MM units responsible for $2.6B in revenue. To increase production while improving satisfaction, they needed to move to a digitized system with an automated quality control process.
Design, Build, and Integration of a Custom MES
We were engaged to help the client with the requirements gathering, design, testing, and training of a custom MES that worked in tandem with their existing WMS and ERP systems. Our team, complete with project and change managers, conducted stakeholder interviews, documented business and regulatory requirements, designed the custom application, performed thorough quality assurance testing, and facilitated team training.
The new MES enabled automatic evaluation of production quality standards. Through skillful project and change management techniques, including classroom and on-floor team training, our client reduced waste and downtime from operator errors and prevented mistakes through equipment integration.
