{"id":6399,"date":"2025-01-06T00:24:11","date_gmt":"2025-01-05T23:24:11","guid":{"rendered":"https:\/\/trace.si\/news\/piramida-72-d-o-o-we-increased-productivity-by-50-percent\/"},"modified":"2026-04-21T09:43:03","modified_gmt":"2026-04-21T07:43:03","slug":"piramida-72-d-o-o-we-increased-productivity-by-50-percent","status":"publish","type":"post","link":"https:\/\/trace.si\/en\/user-experiences\/piramida-72-d-o-o-we-increased-productivity-by-50-percent\/","title":{"rendered":"Piramida 72 d.o.o.: We increased productivity by 50 percent"},"content":{"rendered":"\n

We spoke with Slobodan Antic from Piramida 72 about the introduction of business information systems MES in production and WMS in warehouse, and what advantages they brought.<\/p>\n\n

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Before the introduction of MES systems, errors were constantly occurring in the production of products, which led to low productivity and dissatisfied customers. Mistakes were repeated, but now they are no longer like that. <\/strong>.We increased productivity by 50 percent, says Slobodan Antic, director of operations at Piramida 72.<\/p>\n\n

The company Piramida 72 from \u0160abac is one of the successful Serbian companies. It is the leader on the domestic market, generating almost half of its revenues from exports. They also plan to increase sales this year and will build a new production hall. They were also successful because they introduced a production management system (MES) and a warehouse management system (WMS) into the company. In the implementation of MES and WMS, they cooperate with the Ormo\u017e supplier of integrated business information solutions, Trace BS. <\/p>\n\n

We also know about your Fresh wet wipes and shampoo brand on the Slovenian market. Can you briefly introduce the company Piramida 72 from \u0160abac? <\/strong><\/em>Piramida 72 is a family company founded in 1993 with the desire to offer users products for personal hygiene and cosmetics. Today, we have around 350 employees and we are the market leader in children’s wet wipes, liquid soaps, napkins and paper tissues on the Serbian market. Last year (2023) we achieved 32.4 million euros in revenue, and this year (2024) we plan to achieve 35.3 million euros. Half of our income comes from wet wipes, which we export to the markets of fifteen mostly European countries, and we also sell them in Saudi Arabia. Forty-three percent of our income comes from exports. This year we will build a new warehouse and business facility of seven thousand square meters. <\/p>\n\n

How complex are your production programs?We have four production plants with completely different technological processes and technologies.The production of wet wipes and cosmetics is a serial production that depends on the size of the mixer for making emulsions, where it is extremely difficult to produce the exact amount according to the customer’s wishes or the size of the package The production of paper products and packaging is done piece by piece.The specificity of the production of our products is that we have to meet the strict standards that apply to the cosmetic industry, pharmaceutical production and the food industry. We are the only company in Serbia that has achieved the BRC (British Retail Consortium) standard for the production of wet wipes, which is a global benchmark in our industry.Our production portfolio includes 820 products: around 450 of them are wet wipes produced in our wet wipes plant, about 200 are cosmetic products, 150 are various paper goods, and around 20 are blow\u2011molded packaging products. This requires the use of many different raw materials, labeling and packaging methods. Various quality standards must be followed. We face special requirements for maintaining cleanliness and microclimate in production facilities. The production processes vary considerably, and we encounter challenges due to different levels of machine complexity and their intricate settings. A large number of operations take place on the machine centers, operator training for machine handling is complex and time\u2011consuming, and production planning is demanding. <\/p>\n\n

What was the business like before the introduction of the MES system into production?<\/strong><\/em>Before the introduction of MES systems, production errors were constantly occurring, leading to low productivity and dissatisfied customers. Errors were repeated, for example in the composition and labeling of the product. Production waste was hidden or we kept poor records of it. It was impossible to control production, there was no traceability in the use of raw materials, the causes of errors in the process were difficult to determine. Products had to be reworked frequently. Entire assortments of finished products were not appropriate. There was no record of the material used per individual product, there was no record of the work of employees per work order, there was no actual cost price per product.Quality control records (incoming, in\u2011process, and final quality control) had not been transferred into electronic form and were often unrealistic and full of errors.There were no productivity reports by work shifts, nor was there any tracking of working hours, employee arrivals, or departures. We eliminated all these problems by introducing the MES system.<\/strong><\/p>\n\n

What benefits has the implementation of the MES system brought to your production?<\/strong><\/em>We now have complete production traceability, from raw materials to finished products, which enables traceability tests for compliance with QMS and BRC procedures. We also calculate product costs accurately, based on data from work orders that contain information on material consumption and working hours.We are now able to prepare production reports\u2014showing both planned and actual performance by operation\u2014and we have waste reports as well as critical control point monitoring.We now receive a clear overview of the actual raw material consumption per work order and can compare it with the predefined components in order to eliminate scrap in the production process and keep components under control.We have complete data for calculating product cost\u2014direct material costs and labor costs\u2014which is the first requirement for creating cost calculations in accounting.Operational errors have been reduced thanks to end\u2011to\u2011end tracking, from the moment raw materials enter the warehouse to the moment the finished product is delivered. We now have full control over the entire production process. <\/p>\n\n

To what extent has productivity increased after implementing the MES system?<\/strong><\/em>Before the implementation of the MES system, we produced approximately 22,000 to 26,000 pieces of wet wipes per shift and experienced frequent downtimes. Today, the same production line produces approximately 35,000 pieces per shift with no downtime. The increase in production productivity has exceeded 60 percent.Looking at the company as a whole, we have increased productivity by 50 percent, reduced production waste by 80 percent, transferred all quality control department checklists into electronic form, and they are now completed using mobile devices.Thanks to an efficient planning system and full transparency of the raw material warehouse, there are no production delays. All physical raw material inventories are aligned with the accounting records in the ERP system. We have also introduced a performance\u2011based incentive system for production employees. <\/p>\n\n

Which Trace BS solutions does Piramida 72 use?<\/strong><\/em>Piramida 72 has been cooperating with Trace BS since 2016. We use their Trace Solutions software, which includes several different modules. The first solution we implemented was Trace WMS for central warehouse management. Between 2020 and 2024, we implemented the Trace MES solution across all production facilities.We also use the Trace Attendance and Access solution, which provides efficient tools for monitoring employee movement, tracking arrivals and departures, and controlling working hours; Trace Quality for monitoring and implementing quality procedures; and Trace Maintenance for tracking and managing machine maintenance. <\/p>\n\n

What goals do you aim to achieve by upgrading your Trace BS solutions?<\/strong><\/em>Piramida 72 is currently working on integrating Trace solutions with its machines in order to enable machine start\u2011stop control and automatic downtime tracking through the Trace MES system.The automation of work procedures and monitoring processes through Trace solutions in production\u2014and all the advantages that arise from using the Trace system\u2014create new challenges and requirements for the digitalization of other processes, such as HR processes (the company has successfully developed and integrated the HR module in the ERP system with the Trace solution), an R&D module for new product development, a logistics module for static routing of distribution and loading tracking, as well as a module for monitoring customer complaints and integrating them with suppliers. <\/p>\n\n

We maintain continuous collaboration with the Trace team to implement Trace solutions, adapt and enhance the established modules, and further develop them. It must be emphasized that the support provided by the Trace BS staff is exceptionally professional and efficient. <\/p>\n\n

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