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Equalizer plants for the future with SYSPRO MOM

A single platform to improve performance and boost productivity

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Equalizer plants for the future with SYSPRO MOM

Since its inception in 2000, Equalizer has been producing world-class seeding and planting machines, specializing in larger/wider equipment. The company specializes in the design, manufacture and global distribution of planting and seeding equipment for grain production. It has more than 70 dealers across Australia, South Africa, Romania, Ukraine and Zambia, with a production plant covering 9300m².

Their Business Challenge

A long-term SYSPRO client, Equalizer was using another tracking software system, integrated with its SYSPRO solution, to track labor on the production floor. However, the system didn’t provide a comprehensive, true indication of the performance of specific work centers and employees.

SYSPRO Solution

Equalizer implemented SYSPRO’s Manufacturing Operations Management (MOM) solution to fully integrate its manufacturing execution system into SYSPRO and provide a single platform to improve performance and boost productivity.

The Outcome

As a result of the structure and daily scheduling created by SYSPRO MOM, Equalizer has transformed its Fabrication Department from running a week behind to consistently being on schedule, eliminating the previous ripple effect which caused delays in the Metal Finishing and Final Assembly Departments.

“We haven’t regretted choosing SYSPRO for a single day. I can’t imagine being without SYSPRO or SYSPRO MOM.”
– Theodore Turner, Systems Director, Equalizer.

Aligning capacity with reality

With SYSPRO MOM, Equalizer is able to schedule production according to its actual capacity. This provides a clearer, more accurate indication of what needs to be manufactured and whether there are sufficient resources and time to meet requirements.

Theodore Turner, Equalizer’s Systems Director, says: “That’s more in line with our reality. Once the jobs have been scheduled, we can track how each work center is performing in real time and see if it is on track to meet the production requirements. We have a more transparent, accurate picture of performance on the production floor.”

Equalizer operates on a tight schedule, with between 7000 and 8000 orders in the system at any time. Each job order has up to eight operations, and the planters it manufactures have thousands of parts requiring different processes going through a number of work centers. In the past year alone, production levels have increased by 50%.

“It’s always been a struggle to make sure we have enough capacity in the Fabrication Department – and that’s critical, because they supply the rest of the factory,” Turner says. “Today, fabrication is running on schedule with minimal intervention from senior management. Each operator knows exactly what he has to do and can see his performance and Overall Equipment Efficiency (OEE) in real time on his tablet. In addition, the floor manager can quickly see when there are issues in a work center and take corrective action.”

Similarly, Equalizer’s pickers are able to prioritize their tasks according to the MOM schedule. They can see exactly which jobs need to be picked for the day and by what time each specific job needs to be completed. Previously, these jobs were not prioritized, making it more difficult to achieve production targets.

Partnering for success

Equalizer collaborated with SYSPRO partner Lancea Konsult on the SYSPRO MOM implementation, which has been completed in the Fabrication Department. The company is in the process of rolling the solution out to the Metal Finishing and Final Assembly Departments.

“Lancea has an excellent understanding of our business needs and challenges, which is important as there are always some processes that need to be finetuned. As far as the system is concerned, I’m very hands on, and they played a key role in helping us figure out how to get the most out of the solution. We all put in the hours needed to make sure it was successful, and as a result were considerably under budget on the SYSPRO MOM implementation,” Turner says.

Benefiting from enhanced visibility and insights

Commenting on the benefits of implementing SYSPRO MOM, Turner mentions cost savings, consistent quality standards and visibility into the future.

“The need for overtime has dropped, resulting in cost savings, and the system allows us to be more consistent with maintaining quality standards,” he says. “There are three sub-divisions in our Fabrication Department, and each has its own dedicated quality control person. Thanks to SYSPRO MOM, they are able to plan their days more effectively as they know what is being received. All in all, it adds up to a more organized environment.”

The system also provides Equalizer with visibility into the future. The planters are manufactured in batches of eight per week, and each batch is run in SYSPRO which creates job orders and runs Material Requirements Planning.

“This means there are already jobs in the system for the next three to four weeks. We can see well in advance if capacity is going to be strained and take appropriate action. So, the system not only helps us today, but for what’s in the pipeline,” Turner says.

Achieve business success with SYSPRO ERP

SYSPRO is a leading, global Enterprise Resource Planning (ERP) software provider, specializing in key manufacturing and distribution industries. SYSPRO’s ERP solution empowers customers to take the next step – whether it is expanding into new territories, adding new product lines, transforming business processes, or driving innovation.

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