WinMan helps EGL Homecare stay ahead of the competition
Company Size
200-1,000
Region
- Europe
Country
- United Kingdom
Product
- WinMan
- Pegasus
Tech Stack
- Material Requirements Planning (MRP)
- Manufacturing IT Solution
Implementation Scale
- Enterprise-wide Deployment
Impact Metrics
- Customer Satisfaction
- Digital Expertise
- Productivity Improvements
Technology Category
- Functional Applications - Enterprise Resource Planning Systems (ERP)
- Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries
- Consumer Goods
- Retail
Applicable Functions
- Quality Assurance
Use Cases
- Inventory Management
- Manufacturing System Automation
- Process Control & Optimization
Services
- System Integration
- Training
About The Customer
EGL Homecare Limited is a leading European manufacturer of sponges, scourers, and non-woven cloths, based in Shoeburyness, Essex. Established in 1979, the company has grown significantly and now employs around 250 full and part-time staff, with a turnover exceeding £22 million. EGL holds a dominant position in the UK market, with over 75% market share in the all-purpose wiping cloths (retail) sector and 60% in the scourer/sponge sector. The company serves major supermarket and retail groups, producing a mix of 80% manufactured and 20% factored products. EGL's operations involve advanced manufacturing machinery and a high-speed production process to meet the demands of its extensive customer base.
The Challenge
EGL Homecare Limited faced significant challenges due to its rapid growth and the increasing complexity of its manufacturing operations. The company was producing over 1.25 million retail selling units per week, requiring a continuous flow of 15 to 20 truckloads a day. This high production volume put a strain on their existing IT control systems, leading to issues such as lack of plant visibility and difficulties in tracking work order progress. Additionally, the company faced common manufacturing problems like late delivery of raw materials, resource planning and scheduling issues, and movement of Work in Progress (WIP) through the factory. The need for a more robust and efficient system became evident as these challenges began to hinder EGL's ability to meet customer demands and maintain its market leadership.
The Solution
To address the challenges, EGL Homecare decided to replace its existing Pegasus system with WinMan, a more advanced manufacturing IT solution. The decision followed a comprehensive evaluation process, including a six-month business process mapping exercise conducted by an external consultant. The selection process involved visiting manufacturing trade shows and rigorously testing various solutions. WinMan emerged as the clear winner due to its ability to meet EGL's stock control requirements, provide a streamlined Material Requirements Planning (MRP) methodology, and support strategic production planning. The implementation of WinMan was accompanied by necessary hardware upgrades to support EGL's anticipated growth. The company also managed a significant cultural change, training key department leaders who then trained their respective teams. Despite initial challenges, the new system quickly proved its value by highlighting inefficiencies and improving trust in data accuracy.
Operational Impact
Quantitative Benefit
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