AGCEI

AGCEI, designer and manufacturer of transformers, from prototypes to small production runs, works exclusively on demand. This implies a different product mix every month, requiring flexibility and adaptability, especially in production.

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AGCEI in 3 figures

employees

4000

m2 building

% growth

Expectations

In 2023, faced with a significant increase in demand for its coils, the traditional spreadsheet-based planning tools and long-standing ERP system were showing their limits. Production manager Naig had to constantly revise the planning due to the frequent arrival of new orders, rapidly rendering the established schedules obsolete.

This led to delays, lost customers and sometimes complicated business relationships.

Solutions

CONWIP methodology: Implementation of pull flows and operator training.
Rounting : Managers review processes to optimize long-established practices.
Integration of the SmartWip planning tool: Simultaneously with the CONWIP methodology, SmartWip was deployed to plan workshops and monitor production.

The project approach

AGCEI initiated a 6-month transformation in 2023. The project took place in several phases:

Diagnosis: A flow diagnosis was carried out to identify areas for improvement.
Training: Team training in CONWIP methodology.
Work on the Routing: A great deal of work was carried out on the envelope range by Wipsim’s managers and our project manager, optimizing practices established several years ago.
Implementing pull flows: Implementing pull flows in production
Integration of SmartWip: The SmartWip production planning and monitoring tool was implemented in parallel with the CONWIP methodology, providing better management of lead times and increased visibility of the site environment.

Results

Service rate: The service rate increased from 60% to 90% in 6 months thanks to the combination of SmartWip, the planning software and the CONWIP methodology.

Improved customer relations: OTD improvements have benefited business relationships. In addition, the SmartWip simulation provided information on the estimated delivery date thanks to automated planning as soon as the order arrived.

Anticipation: Thanks to SmartWip’s integrated forecast, the production manager has an overall view of future workloads, and can predict the availability of various resources (availability of machines, raw materials, human resources, etc.) as well as potential bottlenecks. This forecast is updated automatically as soon as a last-minute or emergency order is received.

A step back and better management of production orders (POs): Reducing excessive production orders and unclogging the supply chain has resulted in smoother, more efficient management.

Visibility and time savings: SmartWip has given us better visibility on the shop floor, freeing up time for higher value-added tasks.

Automation: SmartWip’s integration with ERP has automated data and improved supply management, avoiding manual actions.

Improved delivery times and cash flow: Streamlined processes have had a positive impact on cash flow, with delivery times back to normal.

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What next ?

AGCEI plans to change its ERP within the next two years to further optimize its processes. In addition, they plan to extend the use of SmartWip to the early stages of the order process for even greater efficiency and anticipation.

With these initiatives, AGCEI continues to demonstrate its ability to innovate and adapt to market demands, while continually improving customer satisfaction through optimized planning!