Avoti's Journey to Manufacturing Efficiency with GlobalReader and Monitor ERP G5
Implementation of digital industry solutions in the world of manufacturing can be a game-changer. This case study explores how Avoti, a fast growing manufacturer of solid pine furniture and wood pellets, embarked on a digital transformation journey by integrating GlobalReader with Monitor ERP G5. Let’s dive into the impact of this integration on Avoti’s manufacturing processes, focusing on the data flow between the two systems and the resulting operational improvements.
The most modern woodworking
Avoti, with over 20 years of experience, has evolved from a small family business into a global furniture supplier. Their journey is marked by constant growth and a commitment to excellence in their field. Additionally, they exhibit a respectful attitude towards natural resources, emphasising responsible and sustainable practices in the manufacturing process.
The Challenge
Avoti desired to improve transparency and efficiency in their manufacturing processes. Furthermore, standardise and unify production statistics across their factory.
They needed a system that could provide transparent, comparable data and objective insights for decision-making, especially in understanding machine utilisation. Getting detailed data from shopfloor into ERP system.
Primary Objective: Identifying the easiest method for shop floor operators to report their work.
ERP System Integration Challenge: Ensuring that operator reports seamlessly integrate with the existing ERP system.
User-Friendly Interface: Finding a solution that offers a simple, intuitive interface for operators to input data.
Comprehensive Reporting Need: Creating a system that allows for complete and efficient reporting within one unified platform.
The Solution
The integration project was approached in stages, starting with the simplest processes and gradually moving to more complex ones. This strategy allowed both Avoti and GlobalReader to understand the data flow and optimise the integration.
The integration began in autumn 2022, focusing on creating a user-friendly system for shop floor operators to report their work.
Data flow from GlobalReader to Monitor ERP:
Setup time
Production time
Operator/employee involved
Workstation where the production occurred
Quantity produced per operation
Quantity of scrap
Reasons for scrap
Data flow from Monitor ERP to GlobalReader:
Orders planned for the workstation
Additional information related to the order
Operation/work center description
Products associated with operations
Order priority list and device groups in order to easily share orders between similar devices.
Key Benefits:
Real-Time Feedback: The integration connects sensor-collected data with production orders in the ERP system, enabling detailed analysis of operations.
Improved Planning and Performance Analysis: Avoti utilised the system to compare machine performances and optimise material flow, leading to the strategic acquisition of additional machinery based on solid data.
Data-Driven Decision Making: The integration enabled Avoti to move from "gut feeling" to data-driven decisions, particularly in setting performance goals and identifying improvement areas.
Dynamic Performance Goals: Allows setting of specific performance targets for each product, accommodating variations in product mix.
Maintenance and Operational Reactivity: The maintenance feature improved equipment management, and real-time data allowed for quicker response to operational issues.
The Results
Avoti experienced a boost in transparency, leading to quicker identification of issues and more informed decision-making. This clarity in operations was pivotal in enhancing overall manufacturing efficiency.
Improved Planning and Efficiency
While an immediate increase in performance metrics is a work in progress, Avoti has already observed improvements. The integration allowed Avoti to refine their planning process by comparing machine performances and optimising material flow. They identified and addressed bottlenecks effectively, leading to see that current machines are already working at top performance and high availability.
Trust and Data
The data flow between GlobalReader and Monitor ERP G5 has enabled Avoti to calculate production costs more precisely, better their pricing strategies, and improve production planning. In addition, enabled Avoti to react faster to issues by monitoring key indicators (read about Factory KPIs here) online and utilising the maintenance feature for better equipment management.
“More trustable data about set-up and run time that goes directly to our ERP system is invaluable. It’s used, for example, to calculate actual production costs. The more precise the data we get, the more precise the price we can set for our products.”
Lessons Learned
Avoti's journey highlights the importance of setting clear goals, having a dedicated project team, and the value of regular testing and collaboration. They recommend similar integrations for manufacturers seeking precise data for performance and availability analysis.
In conclusion, GlobalReader and Monitor ERP G5 integration has helped Avoti into a next step of manufacturing efficiency. By harnessing the power of real-time data and comprehensive reporting, Avoti has not only achieved their initial goals but also opened avenues for continuous improvement and growth. This journey serves as a testament to the huge potential of integrating the right technologies in the manufacturing sector.