Contact Us:  855-335-6442  |  sales@saberlogic.com

Case Study: Whirlaway Corporation

PROJECT:  OEE (Operation Equipment Efficiency) Data Collection

History of Company

Whirlaway was established in 1972 and became a division of NN, Inc. in 2006. Whirlaway Corporation is a world class provider of manufacturing services to the precision metal components industry. Their goal is to produce mission-critical metal components & assemblies better and faster than they can be produced in-house. They are one of just a handful of companies in North America with the in-house ability and resources to build automated assembly and test technology directly into the manufacturing process.

Problem Statement

Whirlaway has two production facilities, each reporting efficiency in different ways. This caused inaccuracies between reports and has made measuring efficiency improvements difficult.

Whirlaway improvement projects are data driven. However, once an improvement project was targeted, the collection of data was difficult, accuracy of the data was questionable, and verifying its effectiveness was challenging.

For years, operators have reported their downtime and scrap by assigning codes to each feature that may be applicable. This data was manually entered into reports making the Interpretation of these records difficult. At times, incorrect machine codes were introduced and time records were incomplete and inaccurate.

Data collection was also being done manually, using several different methods; Excel, database, MRP system. These data collection methods required an additional four full-time associates and a part-time data entry person to support team leaders, supervisors, and engineers. Data entry would often become backlogged and impact the already unstable data reporting. At times, data would be weeks or even months behind, depending on absenteeism and vacation schedules.

Scrap entry into our MRP system was completed by two full-time associates, requiring up to 4 hours of data entry per day.

Regular management reviews of the performance of each facility were difficult because data used by one department would not reflect the same results from another.

Whirlaway developed a plan to address each of these issues. They strategized how the database should function, how data collection could be streamlined and what reports would need to be developed. The system was tested out in Excel format, and once Management agreed on the essential functions that would need to be applied to the database, we contacted outside resources to develop the system.

However, the hired firm did not meet their expectations, and so they began to search for another provider to complete their vision. SaberLogic was selected to review thoroughly what had already been developed to determine what was usable and what would need a complete restructure.

Solution

The appropriate solution involves the creation of a database that would mimic the current paper system yet collect data consistently, accurately and generate comprehensive reports. The database would need to filter data specific for each operation/machine for code selection.

Expectations

  • Reduce costs by eliminating the four full-time data entry positions
  • Achieve timely, accurate and consistent reports
  • Provide a synchronized reporting system by creating a location for central reporting of shared information
  • Develop a user-friendly interface 
  • Utilize their current machine codes system for a seamless implementation process
  • Intergrade the new data with their MRP reporting system for scrap entry, reducing the need for manual data entry

Results

Whirlaway’s new system is being used universally and has the capability to expand and link to other improvement projects, utilizing the same database structure and data entry systems.

The following results were achieved:

  • Removed four full-time data entry positions.
  • Scrap quantities are now automatically reported daily, eliminating the need for any manual entry.
  • Reports are now generated from one central location. These reports include:
    • OEE results per department and process.
    • Build Plan tracking per department and process.
    • Scrap cost/qty per machine/process/department with the option to print applicable scrap codes by the frequency of occurrence.
    • Pieces per Labor Hour reports by machine/process/department and option to print applicable codes by total minutes per category.
    • Rework data – parts scraped due to rework process.
    • Data Review Report – a filtered report that lists the status of each machine, sorted by the process. 
    • Summary report that is used plant-wide in daily production meetings. Within this report is an option to troubleshoot entry errors such as downtime exceeding uptime, scrap entry with no production data and overstated efficiencies.
  • The database uses codes and is formatted to allow ease of entry from the operator’s hard copy to the entry screen.
  • Edit options and access level restrictions are vital for the maintenance of the database.

Cost Savings

  • Elimination of 3 data entry associates positions - $140,000 yearly
  • Reduced workload for two scrap entry personnel - $35,000 yearly
  • Report Generation – reports now take 5 minutes to compile compared to 70 minutes per day for each Supervisor/Engineer/Manager. (20 + associates) Annual savings of approximately $50,000
  • Efficiency Improvements – Project driven savings equal 10-15% for OEE efficiency improvements.
  • TOTAL = $225,000/year

System Cost

  • Initial Program: $52,000
  • Program Improvement: $24,000
  • TOTAL = $76,000
  • ROI = 4 months

Future Improvements

  • Implement a paperless system, eliminating the need for all hard copy production reports and many other manually generated data entry forms.
  • Presenting necessary operating instructions to the operators electronically and updating to these instructions in real-time.
  • Integrating inventory movements into the MRP system for real-time inventory monitoring.
  • Implement a part identification bar-coding system.

 

Crystal Reports Support, Consulting and Programming Services

sl2 crystal

From accounts receivable to inventory to sales, every department of every company has reporting needs. Crystal Reports is an amazing tool to help you pull data from your ERP or database and transform it into information you can use.  

Since SaberLogic started in business in 2002, Crystal Reports support, development and programming services has been a core specialty.  We enjoy being challenged to pull information from multiple sources and deliver Crystal Reports with the right information in unique ways.  

Our Crystal Reports viewer, Logicity, is used by hundreds of thousands of companies to automate and enhance the delivery of those reports   So why not research some of our skills and capabilities below...or just contact us now and lets get that Crystal Reports project off your to-do list!

 

SaberLogic Crystal Reports Development Experience

report developers

  • Versions:  Crystal Reports v7, 8, 9, 10, XI, 2008, 2011, 2013
  • Applications:  Epicor 9, E10 and Vantage ERP, Infor VISUAL ERP, Baan IV, Prophet 21, and more
  • Databases:  Microsoft SQL Server, Oracle, Progress, MySQL, Access
  • Scope:  AR, AP, inventory, job costing, invoice, sales, capacity planning and more

Crystal Reports Support

report support



SaberLogic Crystal Reports Delivery and Scheduling with Logicity

report delivery

  • Print / Email / Save / Export
  • Automated delivery and scheduling
  • Dynamic parameters
  • VBscript and runtime
  • ERP and application integration
  • Security and compliance features




Crystal Reports is a registered trademark of SAP.

Consulting & Support Services for Infor VISUAL Manufacturing ERP

sl2 visual

SaberLogic provides technical services, support and custom development for customers running Infor 10 ERP Express, VISUAL Enterprise and VISUAL Manufacturing.  You will be amazed at what we can do to customize and integrate your VISUAL ERP installation. From EDI, to automated invoicing, to full-on shop-floor mobile, its a very good time to be running VISUAL. Challenge us with your wish list!

 

 

VISUAL is a registered trademark of Infor.

Support, Consulting, & Customization Services for Epicor ERP 10, 9, & Vantage

sl2 epicor

SaberLogic provides support services for customers who run Epicor ERP and who are looking to take advantage of Epicor's amazing ability to be customized and integrated.  Whether you are currently using an older version of Vantage, are up to date on Epicor 9, or implementing Epicor 10, SaberLogic's large team of engineers can provide you with Epicor support, consulting, and programming services to customize and integrate Epicor exactly how you need.  We absolutely love a challenge...why not send us yours!

 



 

 

our customers

 YETI Coolers - a SaberLogic Epicor support customer

 

Agrium Advanced Technology - a SaberLogic Epicor support customer

 

 AccuTrex Products - a SaberLogic Epicor support customer

SaberLogic - YETI Testimonial on Epicor Services

 

For more information on our Epicor services, please contact us!

Epicor and Vantage are registered trademarks of Epicor Software Corporation.

Meet Our Team

SaberLogic - Adam Ellis - Partner - Operations Manager

adam ellis
operations manager


SaberLogic - Brian Ellis - Partner - Business Development Manager

brian ellis
business dev manager


SaberLogic - Eli Remington - Partner - Marketing Manager

eli remington
marketing manager


SaberLogic - Seth Remington - Partner - Architecture Manager

seth remington
architecture manager


SaberLogic - Seth Branan - Custom Development

seth branan
custom development


SaberLogic - Alex Cleveland - Inside Sales

alex cleveland
inside sales


SaberLogic - Kahley Cleveland - Sales Account Manager

kahley cleveland
sales account manager


SaberLogic - Keith Crane - VE Mobile Team Leader

keith crane
ve mobile team leader


SaberLogic - George Curran - Sales Account Manager

george curran
sales account manager


SaberLogic - Priyanka Dubasi - Epicor Custom Development

priyanka dubasi
epicor development


SaberLogic - Amanda Ellis - Accounting

amanda ellis
accounting


SaberLogic - Anna Hodakovskaya - Bezlio Developer

anna hodakovskaya
bezlio developer


SaberLogic - Hilary Hrutkai - Sales

hilary hrutkai
sales - account manager


SaberLogic - Kevin Mansfield - Bezlio Design

kevin mansfield
bezlio design


SaberLogic - Jonathan Miller - Bezlio Developer

jonathan miller
bezlio developer


SaberLogic - Nick Owens - Bezlio Developer

nick owens
bezlio developer


SaberLogic - Kevin Price - Custom Reporting

kevin price
custom reporting


SaberLogic - Robert Schnable - Epicor Custom Development

robert schnable
epicor custom development


SaberLogic - Glenn Smith - Services Manager

glenn smith
services manager


SaberLogic - Andy Spak - Architecture

andy spak
architecture


SaberLogic - Ben Stefancin - Customer Success

ben stefancin
customer success


SaberLogic - Greg Van Riper - EDI Developer

greg van riper
edi developer


SaberLogic - Michael Wagner - EDI Developer

michael wagner
edi development


 
 
 

Photo Credit: Amanda Ellis Photography

10 Year Anniversary Party

 Enjoy some pictures from our special event to celebrate our 10th anniversary on July 29, 2012.

SaberLogic - 10 Year - Front of Building

SaberLogic - 10 Year - Front Window

SaberLogic - 10 Year - Friends and Family

SaberLogic - 10 Year - Friends and Family

SaberLogic - 10 Year - Brian and George

SaberLogic - 10 Year - Nikki and Mike

SaberLogic - 10 Year - Private Bar

SaberLogic - 10 Year - What a Fun Night

 

 

Holiday Schedule

SaberLogic is pleased to announce our 2017-2018 holiday schedule:

2017

  • Monday January 2, 2017 - New Years Day (observed)
  • Monday May 29, 2017 - Memorial Day
  • Tuesday July 4, 2017 - Independence Day
  • Monday September 4, 2017 - Labor Day
  • Thursday November 23, 2017 - Thanksgiving Day
  • Friday November 24, 2017 - Digestion Day and Black Friday
  • Monday December 25, 2017 - Christmas Day
  • Friday December 26, 2017 - Christmas Eve (observed)

2018

  • Monday January 1, 2018 - New Years Day
  • Monday May 28, 2018 - Memorial Day
  • Wednesday July 4, 2018 - Independence Day
  • Monday September 3, 2018 - Labor Day
  • Thursday November 22, 2018 - Thanksgiving Day
  • Friday November 23, 2018 - Digestion Day and Black Friday
  • Monday December 24, 2018 - Christmas Eve
  • Tuesday December 25, 2018 - Christmas Day

New Design. New Logo. New Brand.

newdesign.  newlogo.  newbrand.

First we would like to thank you for your support of SaberLogic. Since we first emerged from a flurry of ones and zeros ten years ago we’ve never lost sight of the value of our customers and our incredibly talented employees.

Our tight knit group of employees started with only four, and now we’ve grown to twenty. It is the inspiration of this great group of unique friends that we’ve remade our brand.

Our employees make our company, and we wanted our new brand to represent their unique backgrounds and talents that make SaberLogic what it is today.

We hope that you enjoy the new face of SaberLogic and we look forward to continue growing with you.

Sincerely,

saberlogic

 

Welcome to the new saberlogic

SaberLogic is pleased to announce that on September 1, 2011 we are unveiling a new "SaberLogic".  What?  New?  Well, since our start in 2002, our marketing materials have portrayed more of a stoic corporate look and feel.   It has served us extremely well for our first 9 years.  But something always felt a bit mismatched.  That image just didn't seem to quite mimic the personality of the people who make up SaberLogic.  We are an energetic, imaginative, and exciting group of people (if we may say so) and that personality has been just itching to get out.

SaberLogic black and white logo   SaberLogic color logo with tagline
So in April 2011 we set out to develop a corporate image that reflected our personality a bit better.  We tossed around words like clean, fresh, edgy, playful, stylish, inviting, and contemporary...all terms we felt described us and how we wanted to portray ourselves to you.  We also wanted to give each of the various areas or departments here their own unique identity in some way.  With those goals in mind we worked tirelessly over the past five months on various designs and ideas that embody the ideals and the personality of the people who work here.   We have developed a new logo, website and other collateral which you will start seeing as early as September 1, 2011.  


We would therefore like you to be the first to be introduced to the new SaberLogic.  It's great to meet you!

SaberLogic business cards



Epicor 9, E10 and Vantage - Our Best Tips and Tricks

Blog Posts with Epicor Tips and Tricks

The following are articles from our blog that focus on various functionality, features, and tips for Epicor 9, Epicor ERP 10 and Epicor Vantage.

Epicor on Reddit

Did you know that SaberLogic helps to moderate the Epicor area of Reddit?  Check out the latest posts!

Epicor and Vantage are registered trademarks of Epicor Software Corporation.

Testimonials

YETI Coolers - Johnny Kubala

YETI Coolers - SaberLogic Testimonial

As a new Epicor 9 customer, SaberLogic has been instrumental in helping us utilize the system to best meet our business needs. From designing and implementing complex customizations for EDI transactions to implementing BPM’s to safe guard our processes, SaberLogic always turn projects quickly and accurately. YETI Coolers is a fast growing company, with limited in house staffing and no Epicor technical experts on staff, so it’s great being able to rely on SaberLogic’s expert staff for anything that may come up.

August 2013

Agrium Advanced Technologies - Jay Hartman

Agrium Adavanced Technologies - SaberLogic Testimonial

Andy was very knowledgeable, professional and accomplished everything we asked for in less time than expected. He has been responsive to our needs as needed after the project and a true pleasure to work with. Having his expertise available to us has made our applications team much more efficient and effective.

August 2013

Whirlaway Corporation - Charlene Brown

Whirlaway - SaberLogic Testimonial

The project had been awarded to SaberLogic after a first failed attempt with another firm. Bob was able to take the project and redesign a program that functions very well. We were very pleased with the transition. We have been able to work as a team to develop a program strategy beneficial for both parties.

August 2013

Accutrex Products, Inc - Mark Beichner

Accutrex - SaberLogic Testimonial

We had to pretty much teach Bob the "tribal knowledge" used to quote our custom products.  He did a good job applying this in the product configurator of Epicor.

August 2013

Tropic Oil - Alex M. Gongar , Information Systems Manager

Tropic Oil - SaberLogic Testimonial

I turned to Brian at SaberLogic for advise on our Intranet development on a specific language.  The instructed me on how to simplify the development process.  Brian’s assistance and guidance went above and beyond what I asked for.  He was very professional, knowledgeable and genial in his service to me.  I love having SaberLogic as my partner and Brian was very helpful.

August 2013

CityLink, City of Wadsworth - Robert Eshelman, IT Director

Bob Eshelman - City of Wadsworth

I just want to make sure you realize how much we appreciate everyone's help on putting this together so quickly. We were in a tough spot ...so, thanks again on behalf of everyone here at the city.

June 2013

Tec4Life - Dave Harris, President

 

Thank you for the professional guidance and direction in making the new tec4life.com a reality.  While this project has been over a year-and-a-half in the works, it thrills me to no end that your patience and support have provided my business with a beautifully functional site that matches the level of quality and service Tec4Life clients now expect.

Your team shares this same value in providing the highest level of quality and service possible, and I greatly appreciated the comfort of being able to 'pop in' the downtown Wadsworth office whenever a question or concern arose that needed the clarity of personal attention.

The idea that you worked with the Tec4Life design files and programmed the site within an environment and language that is compatible with the latest mobile devices is exciting and innovative.  The impact that a matched experience will have when our clients and their family members access the site on any gadget is truly second to none.

I look forward to recommending your services to others, and utilizing your expertise in the near future without reservation.

January 2011

132 Main St., Wadsworth, OH 44281 USA
855.335.6442
sales@saberlogic.com

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