1. Client Overview
A Brisbane-based chemical manufacturer, specialising in protective coating, was facing significant operational challenges due to a lack of integrated systems and standardised processes. Their existing technology and management structure were preventing the company from achieving optimal efficiency and growth.
2. The Challenge
The company was facing two major challenges that were hampering their growth:
- Lack of Unified Document Management and Process Control : They had no centralised system for storing company files, no document numbering system, and no standardized processes for managing, updating, or improving their operations. This disorganization made it difficult for the company to ensure consistent quality and growth.
- Fragmented Software Systems : The company was relying on many different software solutions across various departments, leading to divisions and inefficiencies. Critical tasks like production builds were handled in Excel spreadsheets, outside of a secure system, resulting in poor stock control and workflow inefficiencies.
3. Solution Provided
Brissy Studio implemented two key systems to address these challenges:
- PLM System (Product Lifecycle Management):
- We introduced a PLM system to centralise document management and ensure a structured, systematic approach to process management.
- All company files were unified into a single system, with proper document numbering and standardised processes for managing operations.
- This system also provided the company with the ability to continuously monitor, manage, and improve their processes, leading to enhanced operational control and the achievement of ISO 9001 certification.
- ERP System (Enterprise Resource Planning):
- We implemented an ERP system that replaced the multiple inefficient software systems and integrated all aspects of the business into one unified platform.
- The ERP system managed product builds, bills of materials, stock control, the business outshop, and the equipment workshop.
- It systemized production, secured access, and improved control over inventory, leading to a more efficient operation.
4. Results
The implementation of the PLM and ERP systems resulted in transformative changes for the company:
- ISO 9001 Certification (PLM Impact): The structured and documented processes led to the company achieving ISO 9001 certification, demonstrating their commitment to quality and continuous improvement. This certification subsequently led to securing several multi-million dollar government projects.
- Increased Stock Efficiency (ERP Impact): The company improved stock efficiency by 25% while reducing overall stock levels by 15%, freeing up capital and reducing excess inventory.
- Improved Internal Communication (ERP Impact): The ERP system streamlined internal workflows, reducing unnecessary interruptions and improving communication between departments, creating a more agile working environment. It also improved the training of the new staff by providing clear and precise training materials.
- Business Growth (Combined Impact): Over three years, the company’s annual sales grew by 30% annually, increasing their revenue from $6M to nearly $15M, despite economic downturns.
- Reduced Staff Turnover (Combined Impact): Improved working environment reduced staff turnover by 6%, as the company was able to manage operations efficiently with only 13 full-time employees and 6 casual floor workers.
5. Conclusion
By implementing both a PLM and ERP system, Brissy Studio helped the Brisbane chemical manufacturer achieve remarkable operational and financial success. The integration of these systems not only optimised their internal processes and communication but also positioned the company for significant growth and future scalability. Today, Brissy Studio continues to support the client with ongoing automation and system enhancements as they expand.
