Background

Our client entrusted us with a long-term digitalization project for their main production facility. This was a greenfield implementation. The project plan was designed in multiple stages, incrementally covering various phases of the production process - from intermediate products and quality control to scrap management, finished products, warehouse logistics, packaging, and raw materials.

Solution

We delivered the necessary equipment, including mobile computers and labeling printers and enhanced our WMS with a dedicated Quality Control module (extended to support the management of museum samples), processing of intermediate products, and the reintegration of residual products along with the scrapping of defective products. The system was further upgraded with advanced storage algorithms - enabling batch-based warehousing in both depth and width, optimized for various picking and forklift operations. Additionally, it was designed to meet the specific storage requirements for pharmaceutical products within a single warehouse facility.

Challenges

• Extremely high workload in the finished goods warehouse
• Complex integration with the existing MES system
• Advanced product release algorithms based on quality control samples
• Unstable Wi-Fi coverage across the large factory site
• Heavy utilization of mobile computers and labeling printers

Effects

• Significant financial optimization of the implementation
• Incremental rollout with minimal risk of production disruption
• Increased operational flexibility compared to traditional ERP systems
• Reduced system maintenance costs