Precision-machine Parts Manufacturer Implements Inventory Control and Production Management Solution and Improves Operating Efficiencies
Solution Overview
Customer Profile
Gil-Mar Manufacturing, Inc. is a leading supplier of precision-machine parts in the automotive industry. For more than 20 years, Gil-Mar has supplied its automotive castings to customers in the transportation industry. Large customers include Ford Motor Company and Cooper-Standard Products.
Situation
Relying on spreadsheets and manual tools, Gil-Mar needed to improve efficiency and integration. A comprehensive, integrated inventory control and production system was necessary to maintain high levels of customer service and productivity.
Solution
Working with UHY Advisors, Gil-Mar implemented the AIM Vision Supply Chain Management software to control inventory and monitor manufacturing processes. AIM integrated with current accounting system, Microsoft Dynamics GP.
Results
- Simplified Electronic Data Interchange (EDI) by accessing to information from any workstation
- Increased labor efficiencies by allowing greater employee utilization of the systems
- Increase cash flow by reducing inventory overhead
- Improved inventory accuracy
- Integrated accounting and manufacturing seamlessly with one point data entry.
Full Case Study
Known for their product innovation, outstanding commitment to quality and ability to deliver value to their customers, Gil-Mar Manufacturing, Inc. (Gil-Mar) is a leading supplier of precision-machine parts in the automotive industry. While Ford Motor Company and Cooper-Standard Products top Gil-Mar’s customer list, Gil-Mar supplies its automotive castings to customers throughout the transportation industry and across the globe. Gil Ruicci, who founded Gil-Mar more than two decades ago, and his son, Joe Ruicci have seen Gil-Mar continuously grow and their manufacturing plant run to capacity.
“Gil-Mar was growing and we needed a system that everyone would be able to utilize” said Marce Wojtyca, Gil-Mar’s Inventory Analyst. “We wanted a comprehensive inventory control and production system that would integrate with our current accounting system.” Gil-Mar was doing many tasks manually and with spreadsheets. Their system did not integrate and they lacked reports needed to make solid business decisions in a timely manner. Inventory valuation, in-stock items, setting up production lines and measuring efficiencies were all areas that needed improving. “Ford is our largest customer. They require us to follow specific protocols for accepting orders and shipping notifications,” said Marce. “We have a 15-minute window form the time a shipment leaves our docks to notify Ford. If we don’t, our rating with Ford will suffer and it affects our overall relationship with Ford. We ship nights and weekends all over the world. A system that we could count on along with a company who will be there to support us whenever we needed them is paramount to our continued success.”
“We had several meetings with the IT consultants at UHY Advisors,” said Marce. “They listened to our needs, reviewed our work flow and researched potential solutions that would work for us.” UHY Advisors came back with a recommendation of AIM Vision, the Supply Chain Management software solution from AIM Computer Solutions, Inc. AIM would fulfill the inventory control and manufacturing requirements, and AIM also integrated with the Microsoft Dynamics GP accounting software already implemented at Gil-Mar.
UHY Advisors led the implementation and completed the training on site. “They also helped write customized reports for us that simplified the information our managers need to make quick, solid business decisions,” said Marce. One of the reports created was an efficiency report. This report allowed Gil-Mar to know if they were utilizing their 100 ship-floor employees to the fullest and if they were meeting their production numbers for the day. Gil-Mar was able to improve productivity and make adjustments where needed with this report. “We also know what we are scrapping out each day and if we are utilizing our machines properly,” said Marce. Efficient machines and people are necessary to run a productive manufacturing site.
“AIM Vision is an all-encompassing manufacturing program,” said Marce. “We use it for production control, shipping and receiving. All of our part numbers are received into AIM and we keep our entire bill of materials and routers in AIM. It consumes product when we build it and tracks all aspects of shipping including quantity shipped, date shipped and carrier. We have instant access to inventory levels and we know at a glance the stage of development of a product.”
Another integration point is between the Electronic Data Interchange (EDI) and AIM. EDI is the order receipt method that most of Gil-Mar’s customers require. When the order is received through the EDI system, it is processed within AIM so Gil-Mar knows what they need to produce and ship starting with the necessary raw materials. For example, if Gil-Mar needed to have 5,000 casting parts a month, for six months, to fulfill an order, AIM Vision releases this schedule to the warehouse. AIM Vision will track what has been received in from a raw material standpoint, and track where the product is in the manufacturing process.
EDI also works with communication back to the customer. “Since we have tighter controls on our production schedules and more accurate inventory, we know we are giving the customer the most accurate shipping information,” says Marce. “Our customers received shipping information from us in their terminology and in the way they want to see the information.”
Conclusion
We now have instant access to inventory levels and we know at a glance what stage of production the product is at. Having all of this data allows management to make quick decisions and adjustments where necessary. We also offer better customer service since shipping and customer information is easily accessible.”
AIM Vision will track what has been received in and where the product is in the manufacturing process. “We now have empowered our floor supervisors to make decisions in terms of which production centers need to be working in order to fulfill the orders,” said Marce.
Gil-Mar Manufacturing’s efficiency has improved not only with the implementation of AIM, but with their continued relationship with UHY Advisors. Improve efficiency translates into improved profits and growth. “We are running to capacity,” said Marce, “and we are looking to expand.”
