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Food Manufacturing Company

The Situation

A custom manufacturer of food products for retail and food service customers required new Enterprise Resource Planning (ERP) software and a new Warehouse Management System (WMS) for their facilities in the United States and Canada. Several facilities using the previous WMS software were not using the program’s full capabilities. Further, the manufacturer required additional equipment, customization, and training to establish a new system. There were multiple challenges in several areas including lack of controls, difficulty with third party logistics, and storage, shipping, and inventory discrepancies.

The Solution

MLC & Associates worked closely with the ERP Software vendor to coordinate and implement the WMS, which included configuration, use cases, testing, training, and post-implementation support. To ensure the new system was set up correctly MLC performed testing based on realistic scenarios. MLC then provided training for the client as they practiced the process of ordering from bill of materials (BOM), scanning picking locations, and more. MLC provided post-implementation support and worked with the ERP software vendor to further customize the system for the required needs of the organization.

MLC also supported work between departments, such as coordinating efforts between purchasing and accounting and production. This involved reconciliation of accounts, as well as standardization of Unit of Measure (UOM). In addition, MLC worked with the Logistics Coordinator to develop training regarding scheduling orders and performing pickups. MLC coordinated with the client to resolve inventory discrepancies and helped resolve customer issues, working with third parties, warehousing staff, and other companies to improve the client’s fulfillment rates.

Once MLC completed the ERP software and WMS installation, they began working with another facility to implement an RF Scanning System and hardware requirements. MLC performed system testing to validate operability, and then coordinated the installation and training of warehouse staff for each production line. MLC then helped the client switch from relying on expiration dates for inventory control to using a LPID system that can better control supply. MLC implemented an Inventory Control Transfer (ICT) process in the system, instead of relying on ad Hoc shipping.

As another facility was acquired, MLC provided project management, overseeing the construction and refurbishing of the new warehouse and distribution center. This was beneficial to the client, as it helped to alleviate space and storage issues at another facility. Similarly, MLC implemented the RF Scanning and LPID, creating an efficient warehouse operation.

For finished goods inventory, MLC implemented a First Expired First Out (FEFO) system for better utilization. Further, MLC implemented strict security measures including access control systems, truck gate controls and monitoring, cameras, key cards, and remote controls. MLC assisted with implementing the ERP system at the distribution center, performed troubleshooting and investigations, and implemented corrective actions. MLC trained staff using the new ERP system to leverage data and continue improving the company’s processes.

The Benefit

MLC worked in multiple facilities to provide several types of support, including hardware requirements, support with ERP and WMS implementation, employee training, and more. This drastically improved operational efficiencies by providing increased storage capacity and improved tracking and control of inventory. The employees were more confident in their jobs, and the results were evident with the improved operations and a foreseeable increase in production.