Managing multi-step production processes and complex business procedures is challenging for organisations such as Melco, one of the world's major conveyor equipment manufacturers and largest supplier of idlers and rollers in Africa.
Melco employs more than 400 people, and operates a modern manufacturing plant in Germiston containing four factories. Melco's product range is extensive and its idlers have been successfully utilised in every application in over 75 countries throughout the world. The roller manufacturing plant is capable of production in excess of 4 000 rollers per day, and conveyor structure and bases in excess of 20km per month.
Melco's major challenge is in non-standard items that go through an intensive engineering design and drawing process before being put into production; due to the volume of individual components required for each product, accurately managing and tracking product designs, components and jobs is vital to successful manufacturing of a final product. There are major cost implications if an error occurs during the design or production phases of a project.
Afrisoft Africa takes on challenges
Melco approached Afrisoft to find a solution for its design tracking and production challenges. Afrisoft is the primary distributor of TransLution Software in South Africa, a warehouse management tool designed to make complex production processes in manufacturing and warehousing companies simple.
TransLution is able to capture and process real-time project information and send this information into the business ERP software. It is also able to generate a wide range of reports, enabling organisations to make informed business decisions, as well as providing tracking and traceability of both bulk and discrete products in a production line or warehouse.
Afrisoft worked extensively with Melco to first assess its workflow and process challenges. It then designed and implemented a customised solution to resolve these issues, using a TransLution set-up that integrated with Melco's existing production processes and SYSPRO ERP system.
In order to streamline the engineering design process, the system was established to track the status and location of each engineering drawing as it is developed. By assigning bar code labels to each design, which are scanned at every step throughout the design process, Melco has gained improved visibility during the course of approval and reduced the chance for error when the design reaches production.
Once the project enters production, Afrisoft further customised TransLution Software to track the progress of components and relay process information to SYSPRO. Each item is bar coded as it enters production, and wireless bar code scanners placed throughout each of the four factories capture data linked to specific production jobs at every point during the process.
The data captured in SYSPRO ensures consistent quality standards and provides well-documented reports, including real-time recording of lot number controls, labour, machine usage and quality testing, as well as checking against the bill of materials. Information is presented in custom views on-screen with drill-down, print, and export-to-spreadsheet capabilities, enabling users to map progress and ensure targets are being met. Should an error occur during production, the information gathered in the job is able to provide immediate feedback and analysis.
This management information has allowed Melco to make quick decisions to course-correct processes and ensure the product roll-out happens smoothly.
"This system gives us important information we need to ensure production happens efficiently. The fact that all our systems are integrated to show us information all in one place makes for an incredibly convenient way of working," says Eugene Walters, MIS Manager at Melco.
Afrisoft Africa: finding solutions for everyone
Working closely with Afrisoft, Melco was able to simplify receiving and management of stock, dispatching and shipping processes, and gained improved visibility and tracking of the document flow and production process from start to finish.
Afrisoft Africa provides, implements and supports advanced, tailored technology solutions for the complex requirements of agribusiness, manufacturing, warehousing and distribution companies. Afrisoft offers its clients practical, simple-to-use software and systems that integrate financial information with business operations, resulting in measurable business improvements: efficiency, data accuracy, business control and access to business information.
If you are looking to improve your production efficiency, data accuracy and business control, speak to Afrisoft today and identify and solve the problems in your existing production processes.
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