In response to the growing demands of our customer base and increased manufacturing levels, we recently embarked on a project to maximize our production capacity and improving the quality of our products. This challenge required us to rethink our approach to production scheduling and decision-making, particularly in the context of our unique manufacturing process.
Recognising the need for better visibility into production scheduling, we understood that accurate timing is crucial for timely order fulfilment. Our operations involve multiple runs of bespoke products a critical aspect of our business strategy that any new solution needed to support.
Our search began with exploring various software solutions that could integrate seamlessly with our accounting System. We held numerous meetings with software companies, hoping to find a system that could meet our bespoke operational needs. Unfortunately, none of the existing solutions were up to the task.
Realising that no off-the-shelf solution could meet our needs, we decided to look to develop something ourselves. Our in-house IT team took on the challenge and developed a bespoke system using open-source software, WordPress and React. The new software replaced our outdated paper-based traveller system and provides a more accurate and in-depth view of the processes required to assemble our custom battery packs. This allows us to monitor scraps, product improvements and gives accurate times for our products to meet customer needs while improving the quality of our products.
The new system has transformed our operations in several significant ways:
The development of this app was a collaborative process that involved input from across all departments. We began by reviewing company processes and creating a comprehensive process flow diagram to ensure that the app would integrate seamlessly with our existing system and workflow. Regular meetings were held to discuss project progress, and early testing commenced six months after the initial brief. As expected, additional functionality was added during the development process, and the new system was fully launched 12 months after the project began.
Although we are still in the early stages of data analysis, the app has been operational for three months, and we have already observed improvements to the flow of data throughout departments.
The automation also reduced workload off our sales department which meant they can better serve customers by answering questions and helping customers with their projects.
This innovation has significantly enhanced our company’s performance by improving efficiency, accuracy, and quality in our manufacturing process. By developing a custom solution tailored to our specific needs, we’ve demonstrated our commitment to inventive thinking, product development, and creativity in business. As we continue to refine and expand the capabilities of our new system, we are planning to incorporate Material Requirements Planning (MRP), Enterprise Resource Planning (ERP), and Customer Relationship Management (CRM) functionalities. These additions will drive even greater improvements in the future, ensuring that we remain at the forefront of our industry in both innovation and customer service.
Since implementing the project, it has been recognised by the North East Business Awards, winning the ‘Innovation Award’ for Durham, Sunderland & South Tyneside. It’s the 4th time we’ve won the regional heat at the awards, having won Business of the Year in 2022, the Manufacturing award in 2018 and an Internet award in 2004.
We will now head to the grand final, where we will go head to head with the winners from Northumberland & Tyneside and Teesside regional heats.
The team are excited to celebrate this incredible achievement at Hardwick Hall on Thursday the 3rd October 2024. We wish everyone at the awards good luck and can’t wait to share our success with the other amazing companies in attendance.
