People Process Technology

Logistics

WrxFlo Vision Inspection System

Manufacturing
Global
Multi site
The client

Our global manufacturing client is a market leader in industrial lubrication products, with facilities across Europe, the US and India. Over the past several years the client had been driving internal process improvements but were also looking to drive new levels of process efficiency.

The challenge

The problem the client had was in quality control. The client needed a reliable and efficient system that can accurately inspect products and alert them to any issues. Quality control is an essential part of any manufacturing process but ensuring consistent quality can be a challenge. The Client has thousands of finished goods being shipped across the world.

Prior to being shipped, each part goes through a rigorous process including an inspection and quality checks.  The Client would complete up to 900 inspections a day. The process was extremely manual, it required a lot of paperwork and administrative tasks, and human error played a huge part in the process. The client required the inspection phase of the overall process to be automated.

 

 

 

Process is automated
Paperless solution
The solution

That’s where the WrxFlo Vision Inspection System came in. This cutting-edge system can help businesses reach optimal quality control in manufacturing processes by detecting even the smallest of defects, as well as identifying opportunities for improvement. With its advanced features, such as its high-speed cameras, intuitive software, and powerful analytics, the WrxFlo Vision Inspection System can provide businesses with the insights needed to ensure consistent quality.

WrxFlo looked at our clients current vision system quality inspection process and worked with them to review the portfolio of manufacturing products to agree on which areas would be set up.

WrxFlo used Advantech industrial PCs which are hooked up to industrial cameras through USB ports which are implemented onsite in the client’s manufacturing facility. The first unit is then set up. The system takes a visual record of the unit with a 100% inspection rate, which is approved by the client as 100% quality approved.

The WrxFlo solutions

Once this is created the system starts to learn and the Vision Inspection System can compare other parts to this best-in-class part.

With the click of a button, each part will go through a rigorous inspection testing phase and the VIS can detect any errors with parts. The system then notifies the operator, who can then decide a course of action. The operator can fail it or pass it, and a record of the test will be stored.

This system removes any human error, as it removes the operator’s tacit knowledge, as most quality systems are based on human experience and this system is based on machine learning. This system also removes paper as everything recorded by hand is now removed and the data is recorded and stored in the cloud for future analysis.

 

Our own “WrxFlo revolution” has the potential and trajectory, to establish and maintain our place as a “leader” in our global group… A paperless, real-time reporting workplace is now a reality.

CEO
Manufacturing Firm

Our team has issued every part in stock for this week. Now, our team is working on next week's orders.... This is the power of technology.

Director of Engineering
MedTech Firm

We are very happy to pass our TQM audit. The auditor was very happy to see that we had such an impressive system in place. I would like to say thank you to the WrxFlo team for super support and helping us develop this impressive system.

Global Director
Global Supply Chain 
The result
  • A fully automated system, that can accurately inspect products once they are finished manufacturing and alert them of any issues.
  • Self-learning – as it learns and predict good product and bad product, which allows the client to improve the system accuracy over time.
  • Cloud-based – the platform sits in the cloud; all records are stored on the cloud and on hand to the business in real time for review.
  • Analytics - The system can analyse metrics and trends with errors/faults

WrxFlo Transport Management system

Logistics
IRELAND, THE UK & EUROPE
SINGLE SITE & EUROPEAN FLEET
The client

Our client is a logistics company, shipping parts for multiple different industries and sectors across Ireland, the UK and Europe. Experience and knowledge in freight forwarding, refrigerated and dry cargo, hazardous goods, transport, and import/export documentation.

The challenge

One of our global customers implemented the WrxFlo TMS because they lacked visibility in their systems and operations. It was difficult for them to track a full order in one place and to update customers as to where their order was, at any given time. Our client had two key business applications in place to run its business, one to manage orders and one to track trucks. Both systems ran daily, however it was difficult to extract KPI data to measure performance.

  • The current systems didn’t speak to each other, so there were huge gaps in information.
  • Due to the gaps in information, Itit was difficult to track shipments and to update customers to where their orders were, at any given time.
  • Both systems had to be updated manually, so there was a lot of human error.
  • Truck drivers were having issues with receiving the correct up- to-date data.
  • Issues and problems arising were being missed due to the lack of real-time data insights.
    The company wanted to grow and expand and both systems were unable to analyse issues and prevent them in the future.
Instant KPIs review
Transport tracking
Cloud-based
The solution

WrxFlo introduced the Transport Management system in their facility and created a suite of real-time metrics that connected both applications and allowed the company to extract KPI data to measure overall performance. This addressed any gaps the old system presented and allowed them to address any issues the process posed.  Both applications are now connected in real-time, and the data retrievedd from the WrxFlo TMS provides an enhanced customer experience and better visibility.

 

Our own “WrxFlo revolution” has the potential and trajectory, to establish and maintain our place as a “leader” in our global group… A paperless, real-time reporting workplace is now a reality.

CEO
Manufacturing Firm

Our team has issued every part in stock for this week. Now, our team is working on next week's orders.... This is the power of technology.

Director of Engineering
MedTech Firm

We are very happy to pass our TQM audit. The auditor was very happy to see that we had such an impressive system in place. I would like to say thank you to the WrxFlo team for super support and helping us develop this impressive system.

Global Director
Global Supply Chain 
The result

The biggest KPI’s in Logistics are managed. Which include:
 

  • Real-time visibility of trucks by GPS location
  • Forward planning, to optimise shipments
  • Empty Running (Empty trailers) reduced
  • Truck utilization and scheduling is improved
  • Customer service levels improved
  • Truck and driver performance, which saves time and overall operational costs, as actions can be taken to correct the issues before they occur.

WrxFlo Business Intelligence

Logistics
Manufacturing
supply chain operation
The client

Our clients range from across the global supply chain, including supply chain operation control towers, manufacturers, warehousing, logistics, distributors to third party providers.
With the growth of the business intelligence market, you have the option to choose from a plethora of solutions for accessing, analysing, and deriving value from raw data. Gartner estimated that in 2022, 70% of companies will rigorously track data quality levels via metrics, therefore the rapid adoption of BI is expected.

However, the number is expected to grow further in 2023 as more businesses deploy Business Intelligence solutions. The capacity to harness data acquired, analyse it efficiently, and transform it into business strategies is frequently the difference between succeeding and losing in a competitive environment. As a result, the tools we use to collect, report, and analyse data are critical tools in the workplace.

The challenge

Limited visibility on data across the business

A lot of businesses are seeing that the business management systems within an organisation i.e., ERP, MES, CRM etc are not all encompassing and do not connect to each other. And similarly, the systems linking each supply chain vertical (e.g. manufacturing to logistics to distribution), are also not as well connected as we would like and therefore have excel spreadsheets, hanging off of these applications and large volumes of teams to maintain them.
Therefore, the problem that our clients generally have is that they cannot get an accurate picture of the business to make a well-informed business decision. Due to the information being inaccurate, the business is hugely inefficient.

Instant KPIs review
Consolidated data from multiple excel sheets
Cloud-based
The solution

The solution is therefore the WrxFlo Business Intelligence Platform.
Business intelligence (BI) software is a type of application software that is used to gather, analyse, convert, and report data for business intelligence applications. The applications frequently access data that has already been stored, most commonly but not necessarily in a data warehouse or data mart.

WrxFlo enables organizations to access and connect multiple business systems, such as ERPs, MES, CRMs, and spreadsheets, to provide a single source of truth and valuable insights to help businesses make better decisions and achieve greater levels of efficiency throughout their supply chain.

Our own “WrxFlo revolution” has the potential and trajectory, to establish and maintain our place as a “leader” in our global group… A paperless, real-time reporting workplace is now a reality.

CEO
Manufacturing Firm

Our team has issued every part in stock for this week. Now, our team is working on next week's orders.... This is the power of technology.

Director of Engineering
MedTech Firm

We are very happy to pass our TQM audit. The auditor was very happy to see that we had such an impressive system in place. I would like to say thank you to the WrxFlo team for super support and helping us develop this impressive system.

Global Director
Global Supply Chain 
The result

Accurate reporting enabling better business decisions

Business outcomes:

 

The main Results of the WrxFlo Business Intelligence Software

  1. The business gets early value from the solution as it starts to work immediately and can be implemented in a matter of weeks.

  2. Accurate reporting enabling better business decisions.

  3. Improved Operational Efficiency and capacity by 20%.

  4. Enables cost reduction - Our clients have seen a 15% improvement on transformation costs saving €3M.

  5. Its more sustainable and leaner and removes wasted time and steps from the process.

  6. It improves Customer Delivery by 30% due to visibility of orders through the supply chain.

WrxFlo 3PL

Logistics
GLOBAL
Warehouse Operations
The client

Our client is a global leader in accessories and technologies that empower mobile lifestyles. The company manufactures and distributes screen protection, power management solutions, mobile keyboards, cases, and personal audio.

The challenge

The client has an old ERP system and there wasn’t appetite in the company to invest in a new ERP in the short term, so they needed something to bridge the gap in functionality.

The client has multiple shop fronts globally where they sell to the end user. They needed to supply those stores with product from the origin manufacturing sites which are located globally, so they use third-party logistic providers (warehouses and distribution centres) to manage and deliver products globally.

The other complication was that they have specific products dedicated to specific clients, so there was a lot of inventory dispersed across the globe.

The management team required daily visibility on stock levels and the value of stock across the business in each location.

Reports, KPIs and business insights were challenging to produce due to:

  • Multiple source data points and Multiple varied formats as well as Independent source data points which were not connected
  • The client had a manual process in place that heavily relied on extracting data from at least 20 excel sheets csv files and web applications which was extremely time consuming.
  • Every month employees would generate a report and it would take days to gather, extract and verify the information in a presentable format.
  • When reports were circulated, they were a snapshot of a point in time, that would have been from the past so not all information was in sync, leaving the team to spend hours doing the manual adjustments.
  • While reports provide key business data, it is difficult to produce deeper levels of analytics and insights due to challenges managing in excel.
  • The system was administration intensive.
Real-time data
Removal of all manual steps
Stock valuation
The solution

WrxFlo implemented the WrxFlo (3PL) third party logistics solution into the company. This system bridged the gap in functionality in terms of the additional requirements they needed from the existing 25-year-old ERP system.

 

The system securely connected into the clients’ systems globally and pulled out the required datasets. This enabled the relevant data to be seen, converted, and then transformed into meaningful insights and analytics that management required.

With this, the system has removed all manual steps.

  • Real-time reports are now available to management at the click of a button.
  • The team can now analyse data and trends week on week and month on
  • Instant traceability with instant access to the correct information
  • Predicts problems and points out errors
  • Provides real-time insights and analytics on a single platform
  • Instant access to stock valuation in each location globally

Our own “WrxFlo revolution” has the potential and trajectory, to establish and maintain our place as a “leader” in our global group… A paperless, real-time reporting workplace is now a reality.

CEO
Manufacturing Firm

Our team has issued every part in stock for this week. Now, our team is working on next week's orders.... This is the power of technology.

Director of Engineering
MedTech Firm

We are very happy to pass our TQM audit. The auditor was very happy to see that we had such an impressive system in place. I would like to say thank you to the WrxFlo team for super support and helping us develop this impressive system.

Global Director
Global Supply Chain 
The result
  • This system has saved on average of two weeks of manual processing time to the business each quarter, which is significant time they have gained back to do more valuable activities.
  • The client now has visibility to their entire supply chain globally in one platform.
  • WrxFlo bridged the gap in functionality from the client’s 25-year-old ERP to providing them with daily visibility to their stock levels as well as the value of the stock across multiple locations globally
  • Decisions can be informed with real-time data and made much faster than before
  • Wrxflo have removed all the manual steps providing a more automated approach.

WrxFlo Warehouse Management System

Manufacturing
Global
Multi site

The client

Our global manufacturing client is a market leader in industrial lubrication products, with facilities across Europe, the US and India. Over the past several years the client had been driving internal process improvements but were also looking to drive new levels of process efficiency.

The challenge

The company managed thousands of parts daily and the process
for managing parts across multiple sites globally was extremely manual
The company lacked visibility on material availability. They had challenges meeting shipping dates and they lacked control of inventory across multiple sites.  This resulted in poor production capacity and efficiency which meant they were falling behind their peers in their sister sites globally.

 

 

 

 

Instant KPIs review
Inventory tracking
Cloud-based

The solution

When asked what distinguishes the WrxFlo Warehouse Management system from all the others out there, Ken Sheehan, CTO of WrxFlo said:

“Unlike other warehouse management that usually take a one size fits all approach, our WMS is tailored to our client’s specific needs. Our WMS can cater to and accommodate items of different sizes that are coming into the warehouse, this is something some of our competitors haven’t quite figured out yet. Like most of our solutions, we take the requirements of the client into account first and to the best of our capability create a solution that would fit their exact needs.”

  • The system works by connecting to the clients ERP system. This can also be set up where a facility does not have an ERP, Wrxflo can connect to other business systems onsite to pull in the relevant inventory position.  The new module manages the businesses inventory from the supplier to the company’s location. The system has full control of the inventory levels. The solution is also designed to track the consumption of inventory, and in-house machine parts. The system works using a QR scanning system, which is implemented throughout the manufacturing process. The system can be implemented, across multiple warehousing locations globally for the same company.
  • The WrxFlo WMS is designed to track inventory consumption and in-house machined parts as it has full control of the inventory levels. The system works using a QR scanning system implemented throughout the manufacturing process, this is used to scan the product into stock, and everything is automated after that. The system can be implemented, across multiple warehousing locations globally for the same company, which makes it an ideal solution for scaling companies.

Our own “WrxFlo revolution” has the potential and trajectory, to establish and maintain our place as a “leader” in our global group… A paperless, real-time reporting workplace is now a reality.

CEO
Manufacturing Firm

Our team has issued every part in stock for this week. Now, our team is working on next week's orders.... This is the power of technology.

Director of Engineering
MedTech Firm

We are very happy to pass our TQM audit. The auditor was very happy to see that we had such an impressive system in place. I would like to say thank you to the WrxFlo team for super support and helping us develop this impressive system.

Global Director
Global Supply Chain 

The result

 

  • A customised WMS catered to the business requirements.
  • A Live system that can be viewed anywhere in the business, on any device, once approved.
  • Tracks inventory that has come from external suppliers as well as in-house machined parts.
  • Visual KPI Dashboard which prompts the warehouse team to action.
  • The data is fully recorded, so full track and trace for inventory.
  • All the features of a typical WMS including Cycle counting, aged inventory management
Click here to find out how WrxFlo Warehouse Management System helps transform your business.

WrxFlo Digital Manufacturing

Manufacturing
Global
Multi site
The client

Our client is a global manufacturing client with a manufacturing facilities based in Ireland, the United States, China, France, Germany, the United Kingdom, Austria, Ireland, India, and Spain. The client produces Industrial Lubrication products for the global Market.

The challenge

The management team were looking for new levels of process efficiency across the company. The company relied heavily on paper daily. They had a 25-year-old ERP system in the business which they wanted to replace, and they were experiencing process challenges including:

  • Limited management and KPI reports
  • Poor visibility on how process was preforming real-time
  • Poor visibility on material availability for shop orders
  • Tools and gauges often missing and difficult to find to start jobs
  • Parts often missing to complete orders
  • Meeting shipment dates was a challenges
  • Escalations across functions was a daily occurrence
  • Difficult to increase factory capacity
Productivity improved by 25%
Capacity increased by 30% with no additional headcount or equipment
99% reduction of paper
The solution

There were two solutions added to the business to fix this challenge which are part of the Digital Paperless Manufacturing system.

  1. WrxFlo Operator Screen
  2. Business Intelligence reporting

The WrxFlo Operator Screen is a cloud-based solution that meets the modern challenges faced by manufacturers across the globe. The solution works to eliminate a manufacturing paper-based process which drives inefficiencies and utilisation issues.

How it works:
The operator screen solution is connected into the businesses main data sources - Business Management Systems (ERP, MES, CRM etc). This helps eliminate the paper-based process steps. This system then, brings together, everything an operator needs for the job. The data now sits within the system and is on a screen in front of the operator which they can use at the touch of a button.

The Operator Screen is housed in each workstation in manufacturing, so now, the operator uses it as their digital instruction. The system contains a list of the tools required for the job, the design spec, the materials required, the output required for each operator, therefore making the process more efficient, measurable, and actionable

Business Intelligence reporting - On top of this solution, the business decided to add on the business intelligence reporting, which allowed them to access a stream of reporting so they could view their operations in real-time and allowed them effectively to run a paperless manufacturing process.

How it works:

Each operator screen is connected, which therefore means the data is aggregated digitally for management to review in real time.
All the information is then captured on a management Dashboard so the overall productivity, utilisation, and equipment effectiveness can be seen easily in real-time.

 

Our own “WrxFlo revolution” has the potential and trajectory, to establish and maintain our place as a “leader” in our global group… A paperless, real-time reporting workplace is now a reality.

CEO
Manufacturing Firm

Our team has issued every part in stock for this week. Now, our team is working on next week's orders.... This is the power of technology.

Director of Engineering
MedTech Firm

We are very happy to pass our TQM audit. The auditor was very happy to see that we had such an impressive system in place. I would like to say thank you to the WrxFlo team for super support and helping us develop this impressive system.

Global Director
Global Supply Chain 
The result

The Manufacturing client now has an entire suite of data and metrics

Business outcomes:

  • The Operator now has all the data is in one place, so the operator does not have to go looking for anything to put the job together - Visibility on tools, gauges, drawings, material status are all on the system.
  • The Supervisor now can now, manage shop floor orders, manage work orders through production floor, Visibility of downtime and issues, Optimise shop floor with machine learning insights.
  • Management has now visibility of the entire factory, inventory, customer experience etc.
  • 80% reduction in customer overdue orders.