MRP Case Study: D & G Moulding Ltd
123Insight replaced a series of Excel spreadsheets and 'bits of paper on the wall'. D & G Moulding is now completely paperless, improved lead times from three weeks to five days, reduced stockholding by 10% and increased business by 200% without an increase in staff.
Business growth of 200% without staff increase
- Stock reduced by at least 10%
- Stock inaccuracies reduced by at least 5%
- Lead times reduced from three weeks to 5-8 days
- Now completely paperless
- Improved purchasing power due to visibility
D & G Moulding Ltd, based in Alton, Hampshire was founded in 1999 and provides design and manufacturing services for the plastic injection moulding industry. With a staff of five, production ran using a series of Excel spreadsheets, however this caused many problems. Said David Ivey, Company Secretary; “One of the major problems we had was co-ordinating work. We had no visibility of when work was required and often relied on sticking bits of paper on the wall to plan our workload. Although at the time we were small and could get away with that we knew that we had to look at systems that could handle it better.”
D & G decided to evaluate four MRP systems and selected 123Insight. Said David; “123Insight stood head and shoulders above the others. We had planned to narrow our selection down to two systems and spend more time evaluating, but decided to take the training instead to evaluate the software in a live environment before effectively making a commitment. As we were paying a monthly subscription, if it did not work out we wouldn’t have lost much."
Four years on and we've seen the company grow by 200% with no increase in staff. 123Insight has delivered everything we were looking for and has become an integral part of our growth.
Two staff were sent on training to learn the system. Of the training David commented; “We learnt the system very quickly - in fact when we came away from the training we felt that we were fully able to use it.” As business continued to increase D & G delayed implementation, which is a decision that David now rues; “The delay in implementation was purely down to workload and resources. In hindsight if we had implemented earlier we would have made savings in time and effort and made our lives a lot easier. The whole process of implementation was actually very easy. It was also good to have someone at the company holding our hand who was very tolerant of our lack of expertise.”
123Insight went live across all areas of the business and immediately several benefits came to light. “We immediately had visibility; not only of what we were making for the following week, but also much further ahead. As a result we could run larger batches of parts and achieve further economies when buying materials. Our factory is also completely paperless now, with everything immediately available. Lead times went from three weeks to an average of 5-8 days.”
Reporting is also so much easier. Said David; “Previously, to analyse supplier performance we would have to sift through piles of paperwork. Each month we went through that tedious procedure - now it only takes two clicks of a mouse to define a report over a specific time period. Stock holding has reduced by at least 10%, with stock errors also down. In fact overall input errors have reduced as there is no duplication of data entry - once the sales order is raised everything is carried through to dispatch.”
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