Ezata
Data:
October 2019
Category:
APS
Client:
Ezata Industrial
The Company
Founded in May 2002 and located in the largest agricultural machinery and implements production center in Brazil, the EZATA INDUSTRIAL operates in the field of metal cutting and forming, producing quality special parts for various market sectors such as agriculture, road, renewable energy, poultry, among others. Always striving for differentiated customer service, Ezata Industrial is constantly investing in high-tech equipment and software, without neglecting sustainability.
THE CHALLENGE
We have a very large product mix and produce on demand. As a result, our factory is extremely dynamic and has fluctuating bottlenecks, which vary according to the characteristics of the orders in backlog, making production planning and scheduling extremely complex. Before using APS, production order sequencing was done manually, based on ERP information, which typically uses fixed lead times and assumes infinite production capacity. Our team is highly skilled and committed, but manual sequencing was very labor-intensive and prone to errors. Due to the difficulty in quickly responding to unforeseen events and not having 100% confidence in our scheduling, we ended up creating safety margins between processes to ensure on-time deliveries, which generated a large amount of intermediate stocks. Communication between departments was another major issue, as we spent a lot of time looking for information, often having to physically search for parts within the factory to know at which stage a particular order was. With increasing demand, we definitely needed a tool to assist us.
THE SOLUTION
We went to the market to research and concluded that what we needed was an APS (Advanced Planning and Scheduling) system. That's when we came across the Allcance APS Allcance Technology. The implementation was done with great commitment; the professionals from Allcance fully immersed themselves in our process, suggesting improvements and even making changes to the system to meet some of our particularities. We consider this the key factor for the success of the implementation and the results we are achieving. Today, all our scheduling is done through Allcance APS, and we can quickly respond to any unforeseen events that may occur, such as machine breakdowns, urgent orders, changes in customer priorities, idle or overloaded resources. Our PPC has ceased to be operational and has taken on a strategic role in the company, as it can identify problems in advance, simulate scenarios to resolve them, and choose the best options. Having access to process traceability very quickly has greatly improved communication between departments such as sales, engineering, procurement, and manufacturing. Sales have more confidence in promising delivery deadlines, engineering has information on priorities, procurement knows what, how much, and when to buy, and manufacturing has access to the entire production sequence by resource and by sector, the workload of each resource, access to what has been done, what needs to be done, and when it needs to be done, among many other pieces of information.
RESULTS ACHIEVED
RESULTS ACHIEVED
We can say that Ezata has reached a new level in production management after the implementation of Allcance APS. We can mention some of the results we are achieving:
- Knowledge of real production capacity;
- Increased confidence in promising delivery deadlines;
- Reduction in lead time through the factory;
- Reduction of intermediate stocks;
- Reduction of over 80% in time spent creating cutting plans;
- Reduction in setup time;
- Doubled revenue with the same structure, and the factory seems to be calmer;
- Greater predictability in allocating overtime hours;
- Possibility to configure priorities in processes, e.g., Outsourced;
- More organization in purchasing sequencing;
COMPANY DATA
Address: Estrada de Santo Antão, s/n
Neighborhood: Santo Antão
City: Passo Fundo – RS
Phone: (54) 3315-6990
Site: www.ezata.com.br