Earlier this year, we completed a large project with Whirlaway Corporation in Wellington Ohio.  It was a very exciting project that produced very tangible benefits and an impressive 4 month return on investment for Whirlaway.

What business challenges were we up against?  Whirlaway's two different production facilities each reported production efficiencies in different ways.  For example machine operators tracked downtime and scrap by assigning scrap codes.  However, at times, incorrect codes were being used resulting in incomplete and inaccurate records.  In addition, this and other data was being collected manually in a variety of methods and formats.

Without a solid data collection and central reporting foundation, it was difficult for them to implement any improvement projects.  It was not possible to validate results of those projects because the data was questionable and there was such a mismatch between facilities.  The timeliness of data entry was also an issue, with current data often backlogged for weeks to months.

So how did SaberLogic approach this project?  The solution we developed involved the creation of a database that would mimic their current paper system and yet collected data consistently, accurately and generated universal reports. The database was designed to filter data specific for each operation/machine for code selection.  We also made sure to utilize their current scrap codes, making it easier for their machine operators to get up to speed on the new system and new process.  We also integrated the database with their MRP reporting system, reducing any need for manual data entry down the chain.

So were we able to reach the goals we set for ourselves?  Once the project was completed Whirlaway began to see immediate benefits.  Because they were able to eliminate the need for any manual data collection, the equivalent of four full-time data entry positions were eliminated - a savings of $175,000 per year.  Report generation and compilation time was decreased by almost 93%, going from 70 minutes down to 5 minutes.  Over the scope of 20+ associates, this is estimated to save approximately $50,000 per year.  Reporting is now centralized and accurate.

This was only the beginning phase for Whirlaway.  They plan to continue building on this new platform by implementing a paperless system for production reports.  They also plan to push real-time operating instructions to machine operators, integrate inventory movements into MRP for real-time inventory monitoring and implement a part-id barcode system.