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Our client produces tens of thousands of timber components for the bed manufacturing industry every week. This is a more complicated task than it might sound. There are dozens of profiles, hundreds of lengths and thousands of unique products. Although all products start with cross-cutting, many of them also require further operations such as drilling. What we created was named ALTO as it brings several parts of our clients' company ALTOgether.
Managing hundreds of customers and their products is no easy task. ALTO lets users make changes to customer prices quickly and has other customer related tools, such as credit control, built in. Customers are also geo-tagged to show users where they are in relation to other customers on a map.
ALTO allows an order for sets of products to be added quickly. The system then uses the data structure to create a line item for each unique product with the correct quantity. In the past, this was a manual and very time consuming task for the production staff. What used to take 10-15 minutes is now processed by software in seconds.
There is often time to create a stock pack when there is spare timber in the source pack in production. This is completed using the production module which produces a unique label and ID. Because the products are stored with grouped IDs, it is possible to show if there is any stock ready for every order that is outstanding on the system.
The production manager has complete control over production from a simple drag-drop screen. From here he/she can change the order in which orders should be produced, change assigned machines, send messages to machine operators and much more. This has prevented the need to use paper lists that were previously produced several times a day for all machines.
Every item is split into operations. Products with further operations, such as drilling or TNutting, are stored as machining jobs. Since every machine has a touch screen production module, each one can see what jobs are assigned to them and process them when they are complete. This allows office staff to see detail of how every order is progressing through production.
When packs are complete in production, they are instantly made available in the delivery screen. This shows a list of customers with every pack that is available for delivery. With a few clicks, a delivery is created and carbon copy delivery notes are printed in the office ready to the driver to collect.
Credit is made simple in ALTO by allowing customers to have one of three statuses: Clear, Advisory and On Stop. When a delivery is created for a customer on advisory, the system will show the notes saved against them warning of the advisory. Although the user can choose to bypass it, the process makes sure that the right checks are in place. It is not possible to create a delivery for a customer that is On Stop.
Because there are so many customers and products in the system we developed an analysis screen that shows products that are rarely ordered. This list is used to convert those rare products to ones that are very similar but are ordered more regularly. All of this helps to reduce the number of unique products our client has to produce.
In order to manage, you must see. The production analysis section of ALTO allows the production manager to keep track of machine performance. It clearly shows how much each machine is producing and can help highlight any bottlenecks. Another section of the analysis shows how much each machine has assigned to it, so workload is evenly spread.
Given the automated creation of the bill of materials for sets, quick re-pricing and production monitoring, a great deal of admin has been saved by this system.
Service Timber Ltd are a Timber Importer based in Yorkshire. We supply rough sawn, machined and cross-cut timber to a wide range of markets all over the UK.
We have used the development services provided by Foursquare Solutions Ltd for many years. Their first project was to analyse our stock and ordering systems. The company went on to develop a bespoke software solution that allowed us to tightly control our timber purchasing and stock holding.
Since then, Foursquare Solutions Ltd have developed systems for all facets of our business. These systems have greatly improved the operational processes within the company and have facilitated substantial growth.
We continue to engage the services of Foursquare Solutions Ltd and have shown our confidence in their services by commissioning a substantial software system for our machining operations, which will be completed this year. This involves a touch screen workstation at all production machines, which will show the work schedule and will give the operators the ability to sign-off work and produce pack labels. The system will help our production managers control their production workloads far more effectively and it will decrease their administration considerably. We also expect quicker turnaround of orders which we know will increase our margins.
Foursquare Solutions Ltd have always provided an honest and professional service and I have no hesitation in recommending their services to any potential client.
Robert Richardson
Operations Manager
Service Timber Ltd
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