EXAMPLE OF GOOD PRACTICE
-Company: Kovinoplastika Benda d.o.o.
– Industry: production of products and product components in the field of small or light household appliances
– Project: digitization of warehouse and production processes
– Implemented Trace solutions: WMS, MES, PRODUCTION PLAN, PRESENCE, SUPPLIER PORTAL, CUSTOMER PORTAL
– Implementation time: 1 YEAR
Challenges:
- incorrect inventory management,
- a challenge with the time from the production of a certain batch of products to the moment of storage, semi-production phase or delivery to the distributor (aging of the batch),
- difficulties in tracking the locations of materials/products,
- using a system with insufficient data and functionalities
Solution:
- Implementation of Advanced Warehousing and Manufacturing System (WMS) and Manufacturing Execution System (MES)
- Implementation of RFID/barcode technology, terminals in the warehouse and on the machine
- Integration of the Trace solution with the ERP system.
Result:
- +15-25% higher utilization of workers in the warehouse,
- reduction of issuing errors from 3–5% to <0.5%,
- -40% shorter collection time,
- faster inventory execution (previously 2-3 days, now 4 hours),
- 99% accuracy in unfinished phase,
- tracking discarded products and production in real time,
- less workload and greater employee satisfaction
When I look back at the time before the introduction of advanced Trace BS solutions, we were „barefoot“ in some areas. During major outages, we faced errors and stopped production several times because the system showed a situation that was not correct in practice. This led to lower productivity of employees and unnecessary purchase of additional quantities of materials.
We discover how Kovinoplastika Benda achieved exceptional results with the digital transformation of its warehouse and production
About Kovinoplastika Benda d.o.o.
Kovinoplastika Benda is a medium-sized production company with a 40-year tradition. The company, which employs about 130 people, specializes in injection molding and assembly of products and product components in the field of small and light household appliances.
Their biggest customer is BSH, and they are also their system supplier, because Kovinoplastika Benda provides comprehensive technological development for each product. The company, which is characterized by a business philosophy without mistakes, last year thoroughly renovated its warehouse and production information system and reached a new dimension of business.
How did the processes take place before the introduction of digitization and what goals were set in the company?
The initial state of warehouses and production processes was not enviable. In short, this means:
- paper warehouse management
- stock duration up to 3 days
- incomplete tracking of lots
- manual operator reporting on the amount of waste in production
This required the company to set clear objectives:
- 100% lot tracking
- Monitoring of production in real time
- Optimized collection (FIFO, location logic)
- 40-50% faster collection and issuance
- 90% reduction in collection errors
A thoughtful and rational start to the digital transformation of storage - the test phase
Before implementing new digital solutions, it was necessary to analyze the processes and solve the main problems:
– duplication of entries,
– poor visibility of stock in progress,
– incorrect consumption of materials,
– too slow transfer of information to ERP
The company therefore checked the offer on the market and chose Trace BS. They decided to implement Trace Solutions systems, terminals in the warehouse and on the machine, and to integrate with the ERP system. The beginning was cautious and carefully planned. First, they decided to thoroughly test the solution. They set up a test platform in the warehouse and spent three months carefully checking the operation of the system and its integration with other business solutions.
Then they presented the project in “multiple phases”: analysis → pilot project → expansion → training.
The biggest challenges in this were the standardization of locations and cleaning data.
When the test results open the door wide to the implementation of the chaotic storage model
Then followed the implementation of the storage system in the actual environment and its connection with other software solutions at the company level. The Trace WMS solution was implemented in the company at a regional level, with each area requiring between 4 and 6 weeks, also due to the renovation and optimization of business processes. “The full implementation of the advanced system in the warehouse and production required a little less than a year, but that includes the time from the idea to the production solution,” says Todorovic.
Growth in savings and satisfaction in all areas
Trace WMS has provided significant savings for the company and increased productivity of warehouse employees. Kovinoplastika Benda estimates that the advanced storage solution, which is closely linked to production, has resulted in between 15 and 25 percent higher utilization of warehouse workers. Now there are fewer employees there, but they are happier, because they are less stressed than in the past.
Significantly improved employee satisfaction comes at the expense of no more empty walks and movements, no more wasting time looking for materials or goods that are (no longer) there. Materials or products are exactly where the system says they are, employees no longer waste time thinking and searching for missing goods. Trace WMS enabled the company to implement a chaotic storage model.
With Trace WMS, we saved a lot of money, because there are no more material losses, inventory shortages or production losses. The investment quickly paid for itself.
When you know where something is located in the warehouse, how old it is, and where it comes from.
From warehouse digitization with a WMS solution to production digitization with an MES solution
The Trace Solutions company then expanded into production with the Trace MES solution, which ensures absolute product traceability, as it manages the entire supply chain from the entry to the exit of the goods and controls the production processes. The mentioned system also takes care of material labeling and material acceptance to the incoming warehouse in various packaging units, as well as management of internal logistics in the delivery of materials to workplaces, workpieces between work centers and finished products to warehouses. The system also handles the delivery and customized marking of products with labels as requested by customers.
“For each grain of granulate, we know which product it was incorporated into and where it was sent.”
Tracking product changes is of utmost importance, not only for potential bug fixes or design changes, but beyond.
...and we are making ambitious progress with the digitization upgrade
In the next step, together with the Trace Solutions team, we established the recording of key process data from all injection molding machines. We enabled suppliers to use the Supplier Portal and relieved warehouse workers of the burden of receiving goods. We also provide warehousing services with 3PL system. Customers can check inventory and order status through the Customer Portal.
Next steps include the introduction of AGV robots, automated warehouses and advanced AI models to optimize planning. We are aware that digital transformation is a process that does not stop. For a competitive advantage, it is necessary to use all available digital tools.
Are you thinking about digitizing your warehouse or logistics processes?
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