Case Study on WESCOM Group
Replacing Legacy ERP with Modern Solutions
About WESCOM Group
Wescom Group is a world-renowned manufacturer of specialist pyrotechnic products for the global marine and defence industries, producing more than 2.5 million units annually and with a heritage traced back four centuries. Wescom has a reputation for world-class quality and design innovation.
Wescom has specialist manufacturing facilities across four sites in Germany, the UK, Spain and Australia, with a combined area of over 293,000m2 and 250 employees worldwide.
Wescom Group had been using Microsoft AX as their ERP. However, specific processes were time-consuming when it came to record-keeping. Therefore, they could not experience the full benefit of the system, which also caused issues with the business operation. Due to the time-consuming procedures, they experienced backlogs in record keeping; inventory records required updating. Also, some of the processes were done outside of the system on excel files, resulting in duplication of work. For example, Short Interval Control Boards (SICB) were printed outside the ERP system and issued to the shop floor as work instructions. These SICB papers were collected at the end of the day to book the outputs in the ERP system. In addition, due to limitations with the visibility of process steps, the booking of outputs in the system caused backlogs.
The MPS and MRP planning were done outside the system, as planning parameters were not set up/used.
Due to the nature of the products, Wescom must maintain the COMAH (Control of Major Accident Hazards) report, which was maintained outside of the AX ERP system.
Mercurius IT conducted a detailed analysis of Wescom Draycot site’s ERP implementation and suggested Microsoft Dynamics 365 Business Central ERP as a comprehensive fit for the business requirement.
Along with Business Central, the following addons were implemented to enhance the processes:
- Tasklet Factory’s Mobile Warehouse Management System
- Mercurius IT’s Incoming Inspection IP.
- Mercurius IT’s Purchase Requisition for the purchase of miscellaneous products
Enhancements/developments were carried out in the following areas:
- SICB printing and scanning
- Enhancement in Tasklet Mobile to scan the SICB boards for booking production output on a mobile device.
- NCI – Action to be taken for non-confirming items
- Proofing – Create proofing cards and record the proofed inventory when the proofing is carried out.
The SKUs were set up with planning parameters to take advantage of the MPS and MRP planning functionality of Business Central.
Flushing methods were reviewed and applied, allowing the production output at each step to move to the next room when output is booked; this eliminates the annual recording of the movement of semi-finished materials from one room to another.
Wescom’s products are complex and involve multi-level BOMs, which means that manufacturing operations are carried out at multi-level, and the stock is then moved to the next process.
The Tasklet Factory’s Mobile WMS provided an easy interface for receiving items, moving goods within the warehouse, and the issue of materials to the shop floor.
The receiving of materials is also enhanced using Mercurius IT’s Incoming Quality Inspection module. The label printing is done from the inspection module based on accepted and rejected quantities recorded in the inspection.
We developed the SICB module within Business Central, which meant users could create and print the SICB directly from Business Central and issue it to the shop floor at the start of the day. Unlike manual operation, the SICBs can now be printed with barcodes and sequence numbers. Operators record the output details on SICB papers, scanned on the Tasklet device for a speedy booking output.
Development was done to record NCI (Non-confirming Items), and depending on the action on the NCI card, the non-confirming stock is either written off from the stock or moved to a secluded location.
Negative inventory is turned off, ensuring that the correct inventory levels are recorded in the system.
COMAH reports development is done by Mercurius in Business Central enabling the report to be generated from the system.
Requisition of miscellaneous/consumable items is now being done using Mercurius IT’s IP for Purchase Requisition.