Food-Grade and Industrial Phosphorus Processing Company
Client Challenge
š¢ A global phosphorus manufacturer was running disconnected facilities with fragmented production systems and no real-time reporting
š¢ A global industrial-/food-grade phosphorus processor was mandated by Corporate to modernize and digitalize core processes and systems for two manufacturing plants in the US and Canada
š¢ The company struggled with reactive "shooting-from-the-hip" production planning and execution methods
š¢ Their manual, complex, and inaccurate production reporting took days to compile, and month-end financial closing took over three weeks due to disconnected manufacturing and financial systems
Client Solution
š¢ Process Analysis: Conducted Gemba Walks at both factories to perform Complexity Lean Value Stream Mapping and assessed current state of processes
š¢ Master Data Development: Created PDM Master Data Taxonomy for manufactured components, designed inventory lot control systems, and developed structures for regulatory compliance
š¢ Future-state Core Process Standardization: Standardized processes across plants using JD Edwards and Lean frameworks
š¢ JDE ERP Implementation: Configured JDE modules for planning, inventory, manufacturing, and costing, and designed legacy data conversions
š¢ Custom Solution Development: Architected "Hyper Backflush" concept, automated multi-stage Work Order processes, and integrated production with laboratory testing results
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Created centralized dashboards and automated reporting
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Enabled finance, operations, and QA collaboration
Client Impact Results
Planning Transformation: Replaced reactive production planning with sophisticated SIOP process
Reporting Efficiency: Reduced production reporting time from 3-5 days to real-time, automated information.
Financial Close: Decreased month-end closing from more than three weeks to less than one day
Process Integration: Fully automated production and inventory reporting through integration with financial accounting
Operational Proactivity: Enabled management to proactively plan, schedule, and execute in a continuous improvement cycle
Regulatory Compliance: Enhanced tracking capabilities for cGMP and CFR Title 12 compliance.
Client Technologies
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JD Edwards ERP Software
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PLC/Batch process integration tools