Managing complex production

THE APPLICATION has evolved over a number of years to integrate multiple functions and create a highly specialised solution that has helped to improve on-site efficiency, productivity, and performance.

“We use Empirica for stock husbandry,” says Nigel Jameson of Cod Beck Blenders. “We can identify where stock is and more importantly make sure stock is right for the customer. This was our main reason for choosing it and Empirica does this very well.”

Cod Beck Blenders works to exacting standards and it is important to add the precise amount of each component to create the finished product. These amounts are tracked using Empirica so that the company has an accurate and ongoing record of how much stock has been used and remains available – red-yellow-green coding provides a visual cue on admin screens.

When the process is complete, Empirica WMS asks if any remaining stock should be retained in production or returned to stores. If the amount falls below predetermined levels, Empirica WMS will point this out and the stock can be written off. When returning items to store it generates new labels with updated weights and other information. This function, another bespoke development, prevents stock sitting in limbo in production areas, enables a smoother materials flow, and helps maintain a real-time overview of stock held.

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Managing stock for manufacturing like this is inherently more complex than traditional warehousing or distribution. Inevitable changes in demands and requirements can lead to new requirements for features that cannot always be foreseen. There have also been occasions when the company anticipated a requirement, introduced a solution, and then decided a different feature would improve performance.

There have been over 30 modifications to the core system. One example is the ability to track and manage the assays which detail the precise composition of many speciality chemicals. Tracking a single pack of stock is relatively easy but seemingly identical packs can have different assays. If material from multiple packs is used to create a new product its resulting assay can only be determined if the precise assay and amount of each original constituent is known. 

“We needed a way of logging live data from each bag which was quite challenging and difficult to test, but we worked with Chess to get it right,” says Nigel.

Another modification changed the way Empirica WMS manages onsite stock movements. Previously, dedicated trucks worked in each area of the facility and followed instructions issued to them alone by the system. If drivers were busy on other duties the instruction could be delayed before the movement was executed. Also, trucks working in one part of the facility could be busy when those in other areas were idle. 

The system was modified so that each instruction is sent to all trucks. Drivers of any permitted truck can complete any handling task in any part of the facility. Once the movement is completed and confirmed the task is removed from all screens. Similarly, trucks in quiet areas can be sent to work in the busier sections.

“Before we knew it trucks were working all around the site,” says Nigel. “But this is not just about the trucks – it keeps the factory running.”

Principal Logistics Technologies acquired Chess Logistics Technology, creator of Empirica WMS, last year.

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