AMTICO

The Challenge:

OVERCOMING MANUAL INEFFICIENCIES, DATA GAPS AND COMMUNICATION BARRIERS TO DRIVE IMPROVEMENT

Before implementing QAD Redzone Connected Workforce, Amtico relied on a manual, paper-based system for tracking production data. Though office staff were unified in QAD Adaptive ERP, frontline workers had to fill out physical paperwork, which was then archived, transferred into Excel spreadsheets and shared manually. This process was not only time-consuming but also prone to errors, leading to inconsistencies and inefficiencies in data management. Additionally, interpreting floor-level production data from different sources was difficult, as teams often had to work with outdated or incomplete information.

One of the major challenges Amtico faced was the lack of real-time data visibility. Since production data was only reviewed at the end of a shift or even the following day, the company struggled to respond to issues as they occurred. Delayed insights led to missed opportunities for process improvements, making it difficult to optimize efficiency and reduce downtime. The absence of live data also meant that teams were often reacting to problems rather than proactively addressing them.

Another significant challenge was the siloed nature of communication between different departments. Production, maintenance and quality teams operated independently, with limited cross-functional collaboration. This lack of integration made it difficult to coordinate efforts, resolve issues efficiently and drive continuous improvement. Without a streamlined communication platform, decision-making was often slow, and valuable insights were not shared effectively across teams.

The Solution:

LEVERAGING QAD REDZONE CONNECTED WORKFORCE AND QAD ADAPTIVE ERP TO DRIVE DIGITAL TRANSFORMATION

Amtico adopted a holistic approach by implementing QAD Redzone Connected Workforce alongside QAD Adaptive ERP. The connected worker and ERP integration enabled Amtico to modernize both business planning and execution while empowering its workforce through smart manufacturing technologies.

Michael White, Continuous Improvement Technician at Amtico, led the QAD Redzone Connected Workforce implementation and highlighted key improvements: "Before QAD Redzone Connected Workforce, we were manually transferring data into Excel spreadsheets, which delayed decision-making. Now, everything is digital, real-time and accessible across teams."

Key components of QAD Redzone Connected Workforce include:

• Digitization & Real-Time Insights: Over 200 manual data sheets were converted into digital formats, eliminating over 320,000 pieces of paper and reducing the risk of errors.

• Collaboration & Communication: Amtico introduced multiple group chats within QAD Redzone Connected Workforce, including dedicated channels for production, engineering and quality teams. Over 350,000 chats have been exchanged, fostering real-time problem-solving and collaboration.

• Workforce Engagement & Training: With 400 users onboarded, Amtico conducted 140 training sessions covering productivity, compliance forums, action creation and kaizen initiatives.

• Automated Downtime Monitoring: Operators now categorize downtime events in QAD Redzone Connected Workforce. This allows for better visibility into downtime causes and enables project teams to address recurring issues such as machine setup and blade changes.

The Benefits:

EMPOWERED WORKFORCE STREAMLINES OPERATIONS FOR SIGNIFICANT PRODUCTIVITY GAINS

The results of a connected workforce integration, linked with ERP, were significant and quickly realized:

• Productivity Gains: Within the first year of implementation, Amtico achieved a significant improvement in productivity in their Finishing department, resulting in a site-wide 14% uplift in overall equipment effectiveness (OEE).

• Optimized Planning & Purchasing: Improved monitoring and downtime control allowed for better planning and reduced lead times.

• Enhanced Customer Service: Greater visibility into manufacturing data enabled quicker response times and improved schedule adherence, directly benefiting customer satisfaction.

• Workforce Empowerment: Employees were more engaged in decision-making processes, fostering a culture of collaboration and innovation. QAD Redzone Connected Workforce’s built-in recognition tools boosted morale and reinforced positive behaviors.

• Streamlined Operations: The transition from paper-based processes to digital tracking reduced administrative overhead and enabled real-time decision-making, eliminating the lag associated with manual data entry and reporting.

Reflecting on the journey, Ian Lloyd, Operations Director at Amtico, emphasized the value of the seamless integration, stating: "The benefit we’ve seen is the power it has given our workforce. It’s about modernizing working practices and providing a platform that includes our people in the decision-making process."

Ian Lloyd further emphasized the seamless connection between QAD Adaptive ERP and QAD Redzone Connected Workforce: "For Amtico, the value we get really is that it’s a joined-up process. QAD Redzone Connected Workforce is part of QAD, so it’s a seamless process. This makes it easier when discussing upgrades, connectivity and leveraging the joint account, which gives us greater access to the people who can help us with our challenges and upgrades."

Michael White echoed the benefits, highlighting how real-time data and improved communication have driven continuous improvement: "With QAD Redzone Connected Workforce, we’ve opened up our silos. Everyone is more collaborative, and we now have the power to address problems at the frontline."

Amtico’s success demonstrates the transformative power of QAD Redzone Connected Workforce and QAD Adaptive ERP in creating a more efficient, engaged and data-driven manufacturing environment.