Westin Lean Manufacturing Video Case Study 

See how Westin, a kitchen extractor manufacturer in Huddersfield that has been running since 1921, uses WinMan ERP to support lean manufacturing, cut stockholding and take on-time delivery from 50% to 99%.


In this video, Westin explains how lean manufacturing sits at the centre of the business, how the production scheduler lets the customer service team give realistic due dates without interrupting manufacturing, and how the WinMan Go apps built around the warehouse team halved stock-taking time and ended picking errors.

 

Key results from the Westin video case study

  • Cut stockholding by around £50k immediately after going live, which improved cash flow. 
  • Took on-time delivery from 50% to 99% by using the production scheduler to give accurate due dates. 
  • Lets the customer service team quote realistic due dates straight from the production schedule without speaking to manufacturing directly. 
  • Reduced stock-taking time from eight hours to four hours using the WinMan Go apps, which cover picking, shipping and moving stock between locations. 
  • Stopped the picking errors that used to send out the wrong components or the wrong address, so agency staff can now be productive in two days where training previously took too long to be worthwhile.
  • Runs full batch traceability on stock coming in and products going out: "I'm very confident that if we had a serial fault, we'd be able to trace any component back to any customer."
  • Runs standard products, large batches, small batches and bespoke work through one integrated system, described in the video as the main benefit because performance in every department is visible. 

Lean manufacturing ERP FAQs

How does an ERP system support lean manufacturing?
An ERP system supports lean manufacturing by holding scheduling, stock, purchasing and quality data in one place, so waste, over-ordering and idle time can be seen and removed rather than estimated. At Westin, lean manufacturing is at the heart of everything the business does, and it is supported through the production scheduler, the CRM system and the WinMan Go apps. The first benefit was a lower stockholding and better cash flow, followed by more reliable delivery dates.
How does production scheduling improve on-time delivery?
Production scheduling improves on-time delivery by working out due dates from real capacity, materials and work in progress, instead of promising a date based on how long a job usually takes. On-time delivery at Westin moved from 50% to 99%. The customer service team now takes those dates straight from the production schedule without needing to speak to manufacturing direct.
Can mobile ERP apps reduce stock-taking time and picking errors?
Yes. Mobile apps record stock moves at the point the work happens and check each pick against the order, so counts are not written down and typed up later and the wrong part cannot be picked unnoticed. Westin cut stock-taking from eight hours to four hours using the WinMan Go apps, and stopped the picking errors that used to send out the wrong components or the wrong address. Agency staff can now be working on the system in two days, where training previously took too long to be worthwhile. 
Can WinMan ERP be developed around the processes a manufacturer already uses?
Yes. WinMan can be configured around the way a manufacturer already works, and apps can be built for specific tasks rather than the task being changed to suit the software. Westin advised on what they wanted from the warehouse apps and the system was developed around them, covering picking, shipping and moving stock between locations.


Read the transcript from the Westin video case study,
covering lean manufacturing, production scheduling, batch traceability and the WinMan Go warehouse apps with WinMan ERP. 

View full video transcript

00:00:04 - 00:00:29 "Lean manufacturing is at the heart of everything we do, and I don't think we'd be able to do this without the support of WinMan. Based in Huddersfield, we're a manufacturer of domestic kitchen extractors. We employ over 45 people and we've been running since 1921."

00:00:30 - 00:01:01 "WinMan helps support lean manufacturing through the production scheduler, the CRM system, and the WinMan Go apps that we've put in place. It helps us to reduce cost, which every company needs to do. The immediate benefit of WinMan was definitely the stockholding, which appeared to reduce by £50k. Another benefit we saw was the on-time delivery; the production scheduling allowed us to give accurate due dates where previously it was running at 50%, it very quickly went to 99%."

00:01:02 - 00:01:26 "WinMan is very versatile. We make various products: standard products, large batches, small batches, and bespoke products. The system allows us to cope with any type of product coming through. It allows us to communicate easily between departments: accounts, design, manufacturing, logistics. Everybody knows how to use it, it's easy to train, and we have the benefits of having one system."

00:01:27 - 00:01:46 "WinMan provides control over our quality systems. It allows us to control the product through the system with full traceability of batches coming in and where we've sent products. I'm very confident that if we had a serial fault, we'd be able to trace any component back to any customer."

00:01:47 - 00:02:15 "Job scheduling with WinMan is a tool that helps us with bottlenecks. It doesn't eliminate them, however, it allows us to look into the future for potential problems or staffing issues. It allows us to sit back and make a decision based on the information we're getting. It's not just used for manufacturing; the customer service team uses the production schedule to give realistic due dates to the customer without speaking to manufacturing direct."

00:02:16 - 00:02:52 "We have a really good relationship with WinMan. They're not like another company where they'll just say 'this is the system and it can't be developed'. They work with you and understand your processes. With the WinMan Go apps in the warehouse, we advised on what we wanted and they developed the system around us. That allows us to pick, ship, and move stock within locations, giving us full control in the palm of our hands. It's even improved our stock-taking time from eight hours to four hours."

00:02:53 - 00:03:24 "The main benefit we've seen from WinMan Go in the warehouse is picking. We used to have a lot of errors picking the wrong components or sending them to the wrong address. Using the WinMan core system completely stops us from making those errors, to the point where we can now bring in agency staff. Before, it took too long to train them, but now they can be here for two days and use the system straight away."

00:03:25 - 00:03:54 "Our ongoing process with WinMan is to continue with lean processes and bring WinMan in to help us develop more apps. We're looking to bring in a service app for our service engineers and start looking at the CRM system to help us improve customer service. The main benefit for me is the fact that it's integrated, I can see what's going on in each department to see how well we're performing. I'd recommend it to anybody."

 If your factory is promising delivery dates it cannot hit, and your customer service team has to walk onto the shop floor to get an answer, book a WinMan demo to see the production scheduling and WinMan Go apps that took Westin to 99% on-time delivery. 

lean-manufacturing

7 things about Lean manufacturing that is invaluable

Lean Manufacturing

Lean manufacturing is all about maximising productivity while minimising waste in...

Read more...

Resource icon

Cloud Vs On-Premise ERP: How to Choose

Eguide

A guide that discusses the key differences between Cloud, On-Premise and Hosted ERP,...

Download

business-management-software

Automated processes for better quality, productivity and efficiency

Business Management Software

Using automated processes within your manufacturing processes can assist a business...

Read more...

Resource icon

How to Tell You Need a New ERP System

eguide

If you are experiencing these key challenges, it may be time to move to an...

Download

Get in touch

Call today:

844 532 6377

Mon - Fri 8.30AM - 5.00PM


or submit an enquiry: