Integration Increases Scrap Visibility, Drives Down Defects and Costs
Customer Company Size
Mid-size Company
Region
- America
Country
- United States
Product
- GainSeeker
- ERP System
Tech Stack
- Real-time Data Acquisition
- Data Integration
Implementation Scale
- Enterprise-wide Deployment
Impact Metrics
- Cost Savings
- Customer Satisfaction
- Productivity Improvements
Technology Category
- Functional Applications - Enterprise Resource Planning Systems (ERP)
- Analytics & Modeling - Real Time Analytics
- Application Infrastructure & Middleware - Data Exchange & Integration
Applicable Functions
- Quality Assurance
- Process Manufacturing
Use Cases
- Machine Condition Monitoring
- Predictive Maintenance
- Process Control & Optimization
Services
- System Integration
- Software Design & Engineering Services
About The Customer
Hertzler Systems provides seamless, accurate data acquisition solutions for business enterprises and has been in this business for over 30 years. Their customers buy software and services because it is a good investment. With Hertzler's assistance, clients can easily acquire data in any process, analyze that data in real time, and instantly notify process owners of process variation. These capabilities help clients reduce costs, cycle time, errors, and defects, and increase profitability and customer satisfaction. Hertzler Systems' core competencies include providing solutions that enable businesses to make data-driven decisions, thereby improving operational efficiency and overall performance.
The Challenge
High-precision machining company Exacto Inc. tracked scrap data in their ERP system to monitor production and inventory. Once a month, Exacto leadership extracted scrap data into an Excel report for quality analysis. However, the process was cumbersome and the data was often four-to-six weeks old, making it almost useless for timely problem solving and process improvement. Leadership wanted the ability to do more with the ERP system data and wanted timely access to the data. Exacto was a longtime GainSeeker user for real-time shop floor SPC but had never implemented its powerful defect management system due to high labor costs. Manufacturing operations needed scrap data entered in the company’s ERP system to track WIP, inventory, and costing. The quality manager’s need for timely access to scrap data was left on a back burner and never moved forward.
The Solution
Hertzler Systems created an integration process between GainSeeker and the ERP system. The process automatically extracts scrap data from the ERP system and loads it into GainSeeker. Because the integration is automated, there is no additional labor cost to collect the data. The current practice is to extract the data daily, although it could be done more frequently. This integration allows the quality manager, engineers, and other manufacturing leaders to have daily access to scrap counts, defect reasons, and scrap costs. They can track costs for the same product at different points in the process and for different job runs. Exacto leadership can now quickly spot trends in the data and drill down to the root cause of scrap problems.
Operational Impact
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