About Sotech
Since 1982, Sotech has been a leader in sustainable façade solutions, specializing in designing and manufacturing the Optima range of engineered metal rain-screen systems. Collaborating with architects, specifiers, and contractors, Sotech tailors bespoke solutions that meet rigorous fire safety and environmental standards. Their complex manufacturing processes deliver high-quality products such as aluminum, copper, and steel façades. Committed to continual improvement, Sotech holds certifications in quality and environmental standards and is on a path to achieving net zero carbon by 2030.
Operating a bespoke manufacturing model, Sotech produces no items to stock and deals with a high volume of unique products with low repeat rates. Many of their manufacturing processes involve short production times, with items taking less than ten minutes at each stage. This complexity necessitates precise production management and efficient inventory control to maintain quality and traceability throughout their operations.
Project Background
Before implementing Dynamics 365 Business Central and Insight Works’ solutions, Sotech relied on Sage Line 50 and numerous Excel spreadsheets to manage their operations. This combination was insufficient for handling the intricacies of their bespoke manufacturing environment. The lack of integration led to siloed processes, inefficiencies, and data gaps, hindering effective communication across departments.
In March 2020, Sotech embarked on a project to modernize its operational systems. They sought a unified solution to streamline their end-to-end processes—from product design through manufacturing and inventory management—to overcome challenges associated with their previous tools.
Challenges
Operational Complexity: Sotech’s existing systems struggled to manage the intricacies of their custom manufacturing processes. The disjointed nature of Sage Line 50 and Excel spreadsheets resulted in inefficiencies, with critical data often inaccessible or delayed, impacting decision-making and operational flow.
Inventory Management and Tracking: Managing a complex inventory of multiple components and finished goods without real-time tracking led to inaccuracies and stock discrepancies. This affected production schedules and could result in delays or errors in fulfilling customer orders.
Data Collection and Mobility: Relying on manual data collection was time-consuming and prone to errors. Sotech needed automated data collection tools accessible via mobile devices to ensure accurate, real-time data capture at every stage of production and logistics.
Scalability and Adaptability: The existing systems lacked the scalability and adaptability needed to support Sotech’s goals for continuous improvement, stringent quality control, and compliance with safety and sustainability standards. Their non-linear, bespoke workflows required a flexible solution to accommodate their unique business model.
Implementation Process
Sotech initially engaged a UK-based third-party provider for the deployment of Dynamics 365 Business Central and associated solutions from Insight Works. As the go-live date approached, it became apparent that the system was only 80% developed, which posed significant operational challenges. Realizing the need for more specialized expertise, Sotech turned to Insight Works for direct assistance.
Insight Works responded swiftly, deploying an engineer to the UK to provide on-site support. This decisive action and hands-on approach were instrumental in addressing the critical gaps in the system, ensuring its full functionality and enabling continuous production without delay.
Solution Overview
To address their challenges, Sotech implemented a suite of solutions that transformed their operations:
- Automated Product Configuration: By incorporating an advanced product configuration tool, Sotech automated the creation of bills of materials (BOMs) and routings for each custom item and job. This automation reduced manual workload, minimized errors, and ensured consistency across production planning and execution.
- Enhanced Inventory Management: Implementing a robust inventory management system that provides real-time material tracking from receipt to production. Utilizing mobile devices, Sotech streamlined material receipt, lot tracking, and bin management, significantly improving inventory accuracy and reducing discrepancies.
- Real-Time Shop Floor Data Collection: Introducing a comprehensive shop floor data collection solution enabled Sotech to track parts and components throughout the manufacturing process in real-time. This increased visibility, enhanced traceability, supported compliance with safety and quality standards, and allowed for more informed decision-making.
- Mobile Data Collection and Mobility: Deploying mobile devices equipped with data collection capabilities ensured that data was captured accurately and instantly at each stage of production and logistics. This mobility reduced errors associated with manual data entry and improved overall efficiency.
These solutions were fully integrated with Dynamics 365 Business Central SaaS, providing a unified platform that enhanced communication between processes, eliminated data silos, and supported Sotech’s complex manufacturing environment.
Results and Benefits
Since integrating these solutions, Sotech has experienced significant improvements across its operations:
- Digital Transformation of Operations: Transitioning from a paper-based system to a digital platform revolutionized Sotech’s manufacturing processes. Automating BOMs and routings streamlined production planning, reduced manual intervention, and increased efficiency.
- Improved Inventory Accuracy and Traceability: Real-time inventory management provided greater accuracy in stock levels and enhanced traceability throughout the supply chain. This minimized stock discrepancies, ensured materials were available when needed, and improved production schedules, leading to higher customer satisfaction.
- Enhanced Data Accuracy and Efficiency: Automated data collection using mobile devices reduced errors associated with manual data entry. Accurate, real-time data improved operational efficiency and informed better decision-making, enabling Sotech to respond swiftly to changes and demands.
- Scalability and Adaptability: The new system supports Sotech’s bespoke manufacturing processes and accommodates growth without performance bottlenecks. Its adaptability ensures that Sotech can continue to evolve, meeting its goals for continuous improvement, stringent quality control, and compliance with safety and sustainability standards.
- Strengthened Collaboration and Support: The partnership with Insight Works provided invaluable support during critical times. Their responsive assistance and tailored solutions enabled Sotech to overcome significant challenges, turning a potentially failed deployment into a success story.
Key Takeaway
The integration of Insight Works’ solutions with Dynamics 365 Business Central has transformed Sotech’s manufacturing operations. By addressing their unique challenges with tailored, flexible solutions, Sotech enhanced efficiency, accuracy, and scalability. The project’s success underscores the importance of having a responsive and experienced partner when deploying complex ERP systems in a bespoke manufacturing environment.
Additional Information
About Insight Works – www.dmsiworks.com
Insight Works is an Independent Software Vendor (ISV) that caters to the manufacturing and distribution industry. Their product line features a breadth of end-to-end apps that integrate with Microsoft Dynamics 365 Business Central. There are apps designed for manufacturing, distribution, shipping, sales, productivity, barcoding, and more. Apps are distributed through partners like Dynamic Aspect.
