Chemical industry manufacturers Polyseam Limited, based in Huddersfield, West Yorkshire, manufactures private label sealants, adhesives and fillers. Their manufacturing process is unusual in that they have a number of mixing machines which can manufacture the same product, but the methods of manufacture would differ depending on which one is used. For example, the amount of water added or mixing time can change significantly between machines. Their existing production control system was more of a financial package which had been modified to suit their needs, but it was DOS-based and expensive to support, so the company set about evaluating MRP systems to replace it.
Neil Sutulic, IT Manager said; "We were paying up to £3500 per year for customisation on top of the annual maintenance. We also had several other in-house databases, which resulted in a lot of duplicate entry, leading to errors. As options were added to the system over the years menus became impossible to navigate. Reporting was difficult as you had to export all of the data you needed and then filter it through Excel, rather than just generate the report."
Polyseam investigated two other systems in detail, costing up to £90,000 for the software and installation, but even then it was not meeting all of their needs. "We were looking for a lighter system that could be supported internally, which narrowed our search down to SQL-based MRP systems."