EXAMPLE OF GOOD PRACTICE
– Company: Piramida 72 d.o.o.
-Business: Production and distribution of products for personal hygiene, care and household
– Project: Implementation of a comprehensive digital ecosystem in the field of production and storage
– Implemented monitoring solutions: MES, WMS, Attendance and Access, Quality
– Implementation time: gradually, in several phases from 2016 onwards.
Challenges:
- many errors in product assembly and labeling,
- poor records of waste and consumption of materials,
- lack of monitoring of consumption of raw materials,
- insufficient real data on product costs,
- inadequate quality control,
- insufficient analytics and reports (productivity, working hours, employee attendance)
Solution:
- Trace MES - production management and control
- Trace WMS - central warehouse management
- Trace Attendance & Access - monitoring of working hours and movement of employees
- Trace Quality - digitalization of the quality process
- Trace Maintenance - machine maintenance management
Result:
- + 50% increase in company productivity,
- - 80% reduction in production waste
- + 59% increase in the production of wet wipes,
- digitalization of all quality controls,
- harmonized physical inventory with ERP status,
- efficient planning system without delays in production,
- system of rewarding employees based on performance
Our experience with Trace BS has been extremely positive. With a professional approach, we were able to digitize key processes in production and warehouse, which significantly improved our operational efficiency. We now have full production traceability and realistic cost accounting insight, which allows us to prepare accurate reports and make better management decisions. Processes that were previously time-consuming, inaccurate or difficult to monitor have become faster, better and more accurate. With this level of transparency and efficiency, we are now in a position to plan for business growth and expansion with much greater certainty.
Comprehensive digitization of production and warehouse processes and full tracking of materials, work orders and costs.
About the company Piramida 72
Piramida 72 is a regional manufacturer and distributor of personal hygiene, care and household products with more than 30 years of business, more than 400 employees and an annual production capacity of 150 million units. Their portfolio includes more than 350 products and 4 private brands. They distribute in 22 countries on 4 continents. Almost half of their income is generated by wet wipes, which they export mainly to European countries. They are also present in the demanding market of Saudi Arabia. Exports represent 43% of the company’s total revenue.
Logistics and manufacturing: complexity that requires digital integration
Logistics plays a key role in the company. Piramida 72 has 20.000 m² of storage space, and complex production programs require advanced IT and technological support. The company manages a sales and distribution network with four distribution centers in Serbia (Sabac, Čačak, Niš, Belgrade) and its own logistics fleet of over 60 vehicles, which daily supply over 6,600 points of sale for more than 2,200 customers.
Piramida 72 has four key production units, each with a specific technological process:
– production of wet wipes and cosmetics,
– production of paper accessories and packaging,
– production of liquid products (soaps, laundry care products),
– development and testing of products in the laboratory.
Requirements to meet strict standards such as the BRC (British Retail Consortium) and a wide variety of raw materials, labeling and packaging dictate full digital support.
Challenges before implementing the Trace BS solution
First of all, we faced constant errors in production, productivity was low, and customers were dissatisfied. This affected us the most, but at the same time it encouraged us to pursue digital transformation.
Before the introduction of the Trace BS system, the business process of production and control was marked by numerous problems and challenges:
– high rates of errors in product assembly and labeling,
– poor records of waste and consumption of materials,
– lack of monitoring of consumption of raw materials,
– difficulties in determining the cause of errors,
– lack of real data on costs per product,
– manual and inaccurate quality controls without electronic support,
– lack of reports on productivity, working hours and attendance of employees.
Digital transformation and implementation of multiple Trace BS solutions
Piramida 72 has been cooperating with Trace BS since 2016. To date, they have implemented a comprehensive digital ecosystem:
– Trace MES – production management and control
– Trace WMS – central warehouse management
– Trace Attendance & Access – monitoring of working hours and movement of employees
– Trace Quality – digitalization of the quality process
– Trace Maintenance – machine maintenance management
What's changed: Production results today
The MES system and related solutions enable complete monitoring of the entire production process – from incoming raw materials to the finished product. Real-time data on material consumption, working hours and waste enables:
– precise calculation of costs per product
– immediate identification of problems in the process
– automated production of productivity reports
– electronic quality control using mobile devices
Measurable results that speak for themselves
The implementation of the Trace BS solution has brought outstanding results that inspire other manufacturing organizations:
– +50% increase in productivity at the company level
– -80% reduction of waste in production
– increasing the production of wet wipes from 22-26 thousand to 35 thousand pieces per shift
– digitization of all quality controls
– physical inventory aligned with the ERP balance
– efficient planning system without delays in production
– employee reward system linked to performance
We increased productivity by 50% and reduced waste by 80%. With digitized processes, we now have a much better overview of production, data is reliable and available in real time, which allows us to make faster and better decisions. Trace BS solutions have become a key part of our daily operational work.
Looking into the future: digitization as a continuous process
Piramida 72 is currently upgrading its Trace MES system by connecting production machines to automatically track starts, stops and downtime. At the same time, the company continues to digitize other key processes – from the HR module and new product development to logistics and complaint management.
Why does Piramida 72 recommend Trace BS?
Piramida 72 clearly shows that digitization is not an end in itself, but a business necessity for manufacturing companies that want to:
– improve quality and compliance with international standards
– achieve true operational transparency
– increase productivity and optimize costs
– make decisions based on data
We consider cooperation with Trace BS to be a long-term partnership. We especially appreciate their professional support, adaptability of solutions and active participation in further development of the system. I advise the management of other manufacturing companies considering digital transformation to do so as soon as possible. If not today, your competition will take that step tomorrow.
Are you thinking about digitizing your warehouse or logistics processes?
If you are facing similar challenges as described in this case study, we can help you design and implement a solution tailored to your business. Contact us for professional consultation:
Additional information about implemented Trace BS solutions on the example of Piramida 72 d.o.o.:
– Trace MES
– Trace WMS
– Trace Attendance & Access
– Trace Quality
– Trace Maintenance
