How do you run a complex machine shop efficiently without accurate data?
This was the pressing question for Jeff McKay, Vice President at WessDel, Inc. Based in San Jose, California, WessDel manufactures highly specialized components for the aerospace and defense industries. They deal with intricate satellite components, titanium and beryllium alloys, and complex in-house brazing. Their capabilities attract major industry players, but managing such specialized work requires absolute precision on the factory floor.
Unfortunately, WessDel faced a massive roadblock. A severe gap existed between what was actually happening on the shop floor and what their ERP system thought was happening.
If your factory relies on flawed data for production scheduling, capacity planning, and quoting, you operate in the dark. This blog post explores how WessDel transformed its operations using Harmoni’s factory orchestration system. You will learn how they overcame severe data inaccuracies, eliminated wasted time, and achieved a staggering return on investment by bringing seamless automation to their operators.
The Catch-22 of Manufacturing Data
Every modern manufacturing facility relies on data to drive decisions. When management lacks visibility into exact cycle times, operator efficiency, and machine utilization, profitability suffers. WessDel ran a top-tier ERP system, EPICOR Kinetic, but the software is only as good as the information fed into it.
Complex Components, Complex Problems
WessDel is not a standard machine shop. They build mission-critical components that require tight tolerances and specialized materials. Managing this workflow efficiently demands an airtight tracking system. However, WessDel relied on shared computer terminals for operators to log their activities.
Every time an operator needed to clock in, clock out for lunch, or change over a job, they had to walk away from their machine. They waited in line at a shared terminal and manually entered their data into the ERP. Management conducted time studies and discovered a shocking truth. It took operators an average of 11 minutes to complete a single ERP transaction.
When you multiply 11 minutes by multiple transactions per day across an entire team of operators, the loss of productive manufacturing time becomes enormous.
The Double-Entry Dilemma
To fix the data problem, WessDel initially tried installing a standard machine monitoring system. They hoped to get a better handle on machine activity and cycle times. Instead of solving the problem, it made things worse.
The new system required operators to enter their time twice. They had to input data into the ERP system and then enter the exact same data into the machine monitoring software. This double-entry process frustrated operators and introduced even more inefficiencies and errors. The more management asked operators to track their time, the less productive the shop became.
Jeff McKay knew he needed a different approach. As an engineer tasked with improving operations, he needed clean, reliable data to identify problems and implement fixes. He set out to find a solution that would orchestrate their factory without burdening his team.
Orchestrating the Factory Floor with Harmoni
WessDel recognized the vital need for data accuracy. They reached out to Harmoni to explore a completely different approach to factory management. Instead of adding another disconnected layer of software, Harmoni offered true factory orchestration.
Factory orchestration connects the machinery, the operators, and the business systems into one unified workflow. It eliminates friction and lets data flow naturally without forcing operators to act like data-entry clerks.
Seamless Integration in Days
Many manufacturing software deployments drag on for months, disrupting production and frustrating staff. Harmoni took a different path. The installation at WessDel was completed in less than a week.
Bob Dorricott, President and Owner of WessDel, noted how easily the system installed. Harmoni communicated flawlessly with both new and old machines across the shop floor. Even better, it worked seamlessly with their existing EPICOR ERP system right out of the box. There was no need for complex custom coding or lengthy IT projects.
Bringing the ERP to the Machine
The most immediate change happened directly on the shop floor. Harmoni eliminated the need for shared computer terminals. Instead, operators gained the ability to conduct their ERP transactions right at their machines using simple, RFID-enabled automation.
Operators received training quickly. They stopped walking across the factory to log their time. They simply scanned in at their workstation. By replacing tedious manual data entry with localized automation, Harmoni instantly captured accurate cycle times and job changeovers.
This simple shift solved the data gap. The ERP finally reflected the true reality of the factory floor because the data collection became an effortless part of the operator’s physical workflow.
Measurable Results That Matter
Implementing new technology must deliver a tangible financial impact. With no upfront costs to implement the system, WessDel looked for immediate improvements. The results exceeded their expectations rapidly.
Massive Productivity Gains
By taking a time-tracking process that previously took 11 minutes and reducing it to mere seconds, WessDel unlocked a massive hidden reserve of capacity. The company gained 17 productive hours per employee, per month.
Think about that metric. Without buying new CNC machines or hiring additional staff, WessDel effectively added nearly two full days of productive machining time for every single operator each month. This reclaimed time translated directly into higher throughput and a significant competitive advantage.
Better Deliveries and ROI
Clean data leads to better business decisions. With accurate capacity planning and scheduling data flowing from Harmoni to EPICOR, WessDel optimized its production runs. The company reduced its delinquent jobs by more than 10 percent.
Fewer late jobs meant a sharp reduction in expensive overtime needed to catch up on delayed shipments. It also resulted in happier customers, improving overall customer perception and satisfaction data. WessDel calculated that the system provided an ongoing financial benefit equal to over five times the cost of the Harmoni system.
Building a Foundation for Continuous Improvement
The initial rollout focused on time tracking and data accuracy, but Harmoni serves as a comprehensive factory orchestration platform. Within the first few months, WessDel began expanding its use of the system.
They rolled out digital work instructions directly to the operator screens at the machines. They integrated program loading capabilities, ensuring operators always ran the correct, most up-to-date CNC programs. They also implemented digital checksheets to streamline quality control processes.
Because the operators loved using the system and appreciated the automation, adoption was high. The Harmoni platform became a major piece of WessDel’s larger initiative to modernize their entire manufacturing ecosystem. It allowed management to focus on both front-end operations and manufacturing excellence.
As Harmoni continues to add features, WessDel is perfectly positioned to gather even more granular data. They can employ this information to drive continuous improvement efforts, reduce scrap, and realize further productivity gains.
Take Control of Your Factory Data
WessDel’s journey proves that you cannot manage a factory efficiently without clean, accurate data. Forcing skilled operators to perform manual data entry at shared terminals drains productivity and ruins data integrity.
True factory orchestration bridges the gap between your machines, your people, and your ERP. By automating data collection at the source, you empower your operators and give your management team the visibility they need to make profitable decisions.
If your factory suffers from inaccurate tracking, delayed shipments, or frustrated operators, it is time to evaluate your workflow. Look at your shop floor and ask yourself how much time your team wastes just telling your ERP what they are doing. Reclaim that time, clean up your data, and orchestrate your factory for maximum efficiency.
