YAWAL has increased production efficiency thanks to IFS Applications™

For 20 years, YAWAL has been using the IFS Apps 99 version. The system though had become very outdated, with an archaic, not very intuitive interface. The system handled basic company processes, however, there came a need to change and grow with external applications that facilitate our users’ work and the expanding functionality required for our business to grow.

IFS Apps 99 was unable to support business processes in today’s reality. External development work and interfaces also significantly limited flexibility making changes to the application configuration. Such a model could not be further sustained, hence YAWAL decided to update its existing systems.

The implementation was not carried out as an upgrade of the solution but as a complete re-implementation. New processes have emerged in our business and we needed to adapt to the requirements of the third decade of the 21st century. YAWAL has increased production efficiency thanks to IFS APPLICATIONS 9.

As part of the agreement, not only the way of handling the application implementation was changed, but also the implementation process. Similarly, as in the previous implementation in 1999, the focus was on the benefits we could achieve and expect, what the company is supposed to gain thanks to the new implementation, and not on “patching” the shortcomings of the old version.

Data between IFS Apps 9 and two large external functionalities that could not be handled in the ERP application (spatial structure design system and the software for the maintenance-free fully automated warehouse) have been bi-directionally integrated. Additionally, a decision was made to relieve the IT department of server load by placing the entire IFS Apps 9 installation in the POLCON cloud infrastructure.

YAWAL operates a complicated production model, including the implementation of the entire production process in direct connection with the customer’s order. Additionally, production planning is complicated by a very wide range of colours. The individual colours are unique to each customer and cannot be sold to other customers. Therefore, it was decided to use the customer-order configuration module (CTO), along with multi-level demand planning in production orders (DOP).

Particular attention was paid to the proper organization of the workflow between individual cooperating departments. All of this was done to keep to those agreed upon registration orders, delivery dates communicated to customers, for which the Multi-Level Availability Planning (ATO) functionality and tool were used.

The operation of the production module has been remodelled, focusing not only on general material accounting but also on resource and personnel planning. We developed and launched a planning model for all production departments in the company. Statistical Planning and MRP methods are used consciously and effectively.

All production processes are reported on an ongoing basis using wireless terminals with barcode readers. This reporting is done by employees of various production departments, directly by people working on the production line at the start and end of individual processes. The system automatically settles raw materials, working time of individual shifts, allows for automatic printing of labels and also for marking products when they leave the production.