People Process Technology

Manufacturing

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.

Providing real-time process insights across multiple sites for this FinTech client

FinTech
Europe, Asia & South America
Multi site
The client

Connecting three continents and almost 3,000 employees for this global FinTech

This FinTech client is one of Europe’s leading suppliers of mobile point of sale (mPOS) payment terminals, with more than 2,600 employees and over three million customers. It operates in a hugely competitive market with low margins, and therefore needs the manufacturing of its products to be as efficient as possible.

The challenge

Vital data received a day late

This Financial Technology company’s products are manufactured by third-party manufacturers in Asia and South America. And due to variances in systems, their management team in Germany had insufficient visibility of what was happening in the factory.

The client was left with little opportunity to deal with issues or influence the processes in real-time.

They would receive reports the morning after a production run was complete, but they needed live data to help improve efficiency, yield, quality and capacity.

With bases on three continents coupled with tight margins, visibility of all processes and costs in real-time was vital for the continued success and growth of this client.

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 solution

Remotely connecting three continents

WrxFlo connected all of the FinTech client’s systems across all their manufacturing facilities and presented these on custom screens for the European management team with real-time data available within two clicks.

With reduced international travel due to the pandemic, the WrxFlo team could not visit the client sites in Asia and South America, but we were able to work with teams remotely to set up all systems and fully realise the client's needs.

Specific solutions included:

  • IOT connections to the production process and equipment
  • Real-time data insights, visible on any device, worldwide
  • Real-time line performance, quality, first pass yield, cycle time and productivity
  • Full history record of every product
  • Secure data transactions across several continents
Quality improvements up 20%
Line capacity up 30%
One team managing global operations reduced staff requirements by 60% 
The result

Real-time process visibility

The FinTech client can now see exactly what is on the production line in real-time, with visibility across all of their core processes, including cycle time, test results, and all the metrics that are important to them. The client’s engineering team can now manage process performance remotely from any location, without the need for dispersed teams across multiple sites.

Real-time process visibility now enables the manufacturer to fix any problems immediately, thus minimising delays and wastage.

Business Outcomes:

  • Real-time insights for life-cycle of every product – manufacturing & service
  • Best external TQM audit success ever due to data visibility & accuracy
  • Responsiveness to the quality of a promise at the point of sale increased by 80%
  • One team in one location managing global operations reducing staff requirements by 60% 

IoT connectivity providing full end-to-end visibility between sites in China and US

Electronic Manufacturing
China, Germany & US
Multi site
The client

Creating real-time data visibility for this global technology company

This client is an American multinational computer technology company that develops, sells, repairs, and supports computers and related products and services. It is one of the largest pc companies globally.

The challenge

Customised reporting & visibility 

The client was looking to create real-time visibility and updates on equipment performance across many factories. They reported unplanned downtime that would affect overall productivity and cost. The company wanted to manage the lifecycle of equipment more effectively and efficiently, with a key requirement being the ability to create customised reports and dashboards.

Configure woek schedules globally from one location
Multilingual interface
Solution implemented across large sites on several continents
The solution

Custom dashboard & application

The WrxFlo platform provided the client with an overall dashboard that is customisable as required and shows top-level KPI status.

The application sends actions automatically to ensure that problems are addressed and tracked. The types of actions are:

  • Maintenance down-time alert
  • PM job due for completion
  • Calibration due for completion

The dashboard includes:

  • IOT connectivity to all process equipment via PLCs, sensor retrofits and gateways
  • Maintenance team alerts sent to smart phones and smart watches
  • Full end-to-end equipment lifecycle management
  • Predictive analytics were implemented to predict and prevent problems before they occur
  • Configure shift working hours, working days, add new equipment or spare parts across China and US time zones
  • Multilingual interface

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

Reduced downtime and improved data

The client has reported less downtime due to the WrxFlo platform measuring performance and recording poor performing parts, and has allowed real-time insights across international sites.

WrxFlo has also provided a range of additional benefits for the client:

  • The application has allowed users to drill down to reports showing any level of detail required such as maintenance, operational, environmental reports
  • The application tracks factory, environmental and energy performance
  • Issues are pinpointed and addressed in real-time
  • Paper data collection has been replaced with digital forms, where users can enter data via a tablet, PC or smartphone, e.g. quality data, downtime detail, etc.