Success Highlights

Challenges• Manualplanningboard• Obsoleteshopfloordatacollectionsystem• Increasingcustomerdemands

Solution• EpicorAVP

Benefits• Betterdecision-makingbasedonwhat-if

scenarioinformation• Increasedshopfloorefficiency• Proactiveactionsbasedonconstraints

thatidentifycriticalfactorsintheproductionprocess

• Immediatevisibilityintoproductionscheduleandchanges,toallplantpersonnel

• Costanalysisofdifferentproductionoptions,attheclickofamouse

Company Facts• Location:Warwick,RhodeIsland,UnitedStates• Industry:FoldingCartonManufacturing• Website:www.jaypack.com

Jay Packaging

Epicor Success Story

“The scheduling constraint information provided by Epicor AVP has become a crucial part of our process, and we now use this information exclusively. A scheduler can just click on a job and see if the inks are ready, or when the dies and plates will be available. This has enabled us to become proactive to external factors that have a significant impact on our schedule.”

AngeloGiacchi,ITManager|JayPackaging

A phased approachWhentheinconvenienceofamanualplanningboard,andthehindrancesofanobsolete,unsupportedshopfloordatacollectionsystembecametoomuchtobear,JayPackaging(JPG)ofWarwick,RhodeIsland,beganthesearchforaflexibleandcomprehensivesoftwaresolution.Withmarket-leadingcustomers,thishigh-endfoldingcartonandblisterpackagingmanufacturerneededaninternalsystemthatwouldmeettheincreasingdemandsoftheircustomers.

TheJayPackagingteamwentthroughathoroughtwo-yearselectionprocessevaluatingsixdifferentmanagementinformationsystemsfromleadingsoftwaresuppliers,lookingforasolutionthatwasfullycompatiblewiththeirbusinessneeds.Theynarrowedthechoicesdowntothreefinalvendorsthatwereassessedbasedontheirbusinessbackground,thesoftwareitself,andthesupportoffereduponandafterinstallation.

Success Story – Jay Packaging

“Epicor really understood the products we make, and the needs of the packaging industry more than any

of the other companies or systems out there.”FernandoLemos,VicePresidentofFinanceandAdministration

Afterduediligenceintoavailablebusinesssoftwaresolutions,JayPackagingdecidedthatEpicorAVPwouldmatchthedemandsoftheirbusiness.

Justtwomonthsaftersigningthecontract,JPGwentlivewiththefirststageoftheirphasedsoftwareimplementation.

In-house, out-of-datePriortotheimplementationoftheEpicorAVPschedulingandshopfloordata-collectionmodules,JPGreliedoninternally-developedsoftwareoperatingonanoutdatedlegacyoperatingsystem.“WedecidedtopurchaseEpicorAVPsoftwareinseveralphases.Weoptedtoinstalltheadvancedschedulingandshopfloordatacollectionsystemsfirstastheyweremostinneedofupgrade,”saysAngeloGiacchi,ITmanageratJPG.“Ourlegacydatacollectionunitscouldnotbepurchasedorrepaired,andthesoftwarewasnolongersupported.”

Theschedulingsystemwasindesperateneedofimprovement,withJPGoperatingamanualschedulingboardthatconsistedof2”x2”cardsthathadtobehand-writtenbytheschedulersandthenmanipulatedmanuallyasrequirementschangedandproductionorderswererecorded.

System that fits the business at Jay Packaging“Epicorreallyunderstoodtheproductswemake,andtheneedsofthepackagingindustrymorethananyoftheothercompaniesorsystemsoutthere,”saysFernandoLemos,vicepresidentoffinanceandadministrationatJPG.“AtJPGwewantedasystemthatwouldfitourbusiness.Epicorgaveusthat.”ThesupportJPGknewtheywouldgetfromEpicorwasalsoakeyfactorinthedecision-makingprocess.Epicorhadadedicatedteamon-handtohelpensureasuccessfulsystemimplementation,andwithofficesontheeastandwestcoastsofNorthAmericaandinLeicester,UK,Epicorwasabletooffervirtuallyaroundtheclocksupport.

Seamlessly integratedDuringtheinstallationoftheshopfloordatacollectionandschedulingmodules,theEpicorteamwastheretoassistwiththesmoothintegrationofthenewsoftwareintothecompany’sday-to-dayoperationsandtoofferon-handsupportduringthego-live.AgreatdealofpreparationfromJPGensuredthesmoothnessofthistransition,asdidthethoroughtrainingandsupportofferedbyEpicor.

Beforethego-live,JPGranboththenewandoldsystemsinparalleltoallowthebusyteamattheirRhodeIslandplanttolearnthechangesthatcamewiththeimplementation.JPGalsowantedtoensurethatallemployeeswereconfidentwiththenewsoftware.“Itwasimportantthateachoftheemployeeswerecommittedtothesystem;everyonehadtobeapartofit.”saysGiacchi.

Partial completion, full satisfactionJPGrealizedsignificantbenefitsrunningtheEpicorAVPschedulingandshopfloordatacollectionmodules.Thevisualaspectofthesoftwareandits‘what-if’capabilitieshavebeennotedasgreatfeaturesofthesystemwithmajorbenefits.Thekeyproblemwiththeoldschedulingboardwasitslackofvisibility.“Therewasnoeasywaytoviewandmanipulatesituations;auserhadtowalktotheboardtoseewhichstageajobwasat.Thismadeitverydifficulttoreactefficientlytoanycustomerchanges,”saysGiacchi.WithEpicorAVP,themanagersatJPGhaveaccesstoviewallproductionschedules,inavarietyofdifferentformats.Changestotheplanarevisibleimmediatelythroughthepowerfulforward,backwardandbottleneckloadingoptionsofthesoftware.

Theuseofconstraints,whichidentifycriticalfactorsthatcanaffecttheschedulingofajob,hasbroughtmassivebenefitstotheschedulingoperationatJPG.

“Wedidn’trealizehowbigofanimpactthesewouldhave.Theconstraintshavebecomeacrucialpartoftheprocessandwenowusethemextensively.Forexample,aschedulercanjustclickona

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jobandseeiftheinksareready,orwhenthediesandplateswillbeavailable,”saysGiacchi.“Thishasenabledustobecomeproactive,ratherthanreactivetoexternalfactorsthatcanhaveasignificanteffectontheschedule.”

InJPG’sRhodeIslandplant,customerservice,departmentmanagers,purchasingandschedulersareusingthesystem.Ontopofthis,upto20peopleusetheshopfloordatacollectionsoftwareatanyonetime,recordjobandoperationalactivityasitoccurs,withautomaticupdatesbacktotheschedule.Ease-of-usehasbeenoneofthekeyfactorsintherapidadoptionontheshopfloor.AdditionalusersinJPG’sIndianaplantrunthesystem,enablingtotalvisibilityofloadandcapacityacrosstheentiregroup.

Phasing-in the futurePhasetwooftheimplementationwillbeexecutedintwostages,thefirstofwhichwillseetheinstallationofestimating,theflagshipmoduleofEpicorAVPfollowedbytheremainingmodules.GiacchiandallwhowillbeusingthesystematJPGareeagerlyanticipatingthisnextstage,andthefurtherbenefitsthenewmoduleswillbring.“TheflexibilitythattheEpicorAVPestimatingmoduleoffersisahugebenefit,andthestrengthofthismodulewasoneofthemainreasonsforchoosingthesystem,”saysGiacchi.“Theimplementationwillenableustoquicklyrespondtocustomerrequestsforquotes,andtoanalyzethecostsofthevariousproductionoptions,attheclickofamouse.”

ForJPG,thephasedapproachtotheintegratedsystemhassuitedthespecificneedsoftheirbusiness,andtheynowhaveastableplatformuponwhichtobuild.

About EpicorEpicorSoftwareCorporationisagloballeaderdeliveringbusinesssoftwaresolutionstothemanufacturing,distribution,retail,andserviceindustries.Withmorethan40yearsofexperience,Epicorhasmorethan20,000customersinover150countries.Epicorsolutionsenablecompaniestodriveincreasedefficiencyandimproveprofitability.Withahistoryofinnovation,industryexpertise,andpassionforexcellence,Epicorinspirescustomerstobuildlastingcompetitiveadvantage.Epicorprovidesthesinglepointofaccountabilitythatlocal,regional,andglobalbusinessesdemand.Formoreinformation,visitwww.epicor.com.

The contents of this document are for informational purposes only and are subject to change without notice. Epicor Software Corporation makes no guarantee, representations or warranties with regard to the enclosed information and specifically disclaims, to the full extent of the law, any applicable implied warranties, such as fitness for a particular purpose, merchantability, satisfactory quality or reasonable skill and care. This document and its contents, including the viewpoints, dates and functional content expressed herein are believed to be accurate as of its date of publication, June 2013. The usage of any Epicor software shall be pursuant to the applicable end user license agreement and the performance of any consulting services by Epicor personnel shall be pursuant to applicable standard services terms and conditions. Usage of the solution(s) described in this document with other Epicor software or third party products may require the purchase of licenses for such other products. Epicor, Business Inspired, the Epicor logo, and AVP are trademarks or registered trademarks of Epicor Software Corporation or its affiliated companies, registered in the United States and certain other countries. All other trademarks mentioned are the property of their respective owners. Copyright © 2013 Epicor Software Corporation. All rights reserved.

Success Story – Jay Packaging

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