Customer success story

Streamlining Operations with ERP Automation

Industry
Manufacturing
Location
Malaysia and Singapore
Type
B2B

Products used

Synorex Suite

All-in-one business software providing comprehensive ERP solutions.

Overview: Established in July 2015, TPP Manufacturing Sdn Bhd specializes in the production of Polymer Concrete (PRC) pipes used in sewerage and drainage systems. Located in Batu Pahat, Johor, Malaysia, TPP is a sister company of Japan’s Tokai Hume Pipe Co., Ltd., benefiting from advanced Japanese technology and continuous R&D support.

Challenge: As TPP Manufacturing scaled its operations, they faced several challenges:

  • Operational Inefficiencies: Manual processes were leading to delays and errors in production scheduling, inventory management, and order processing.
  • Lack of Real-Time Data: Decision-making was hampered by the lack of real-time insights into production metrics and inventory levels.
  • Quality Control: Maintaining the high quality of PRC pipes, as expected by their Japanese counterpart, required rigorous monitoring and data tracking.

Solution: We implemented a comprehensive ERP solution tailored to TPP Manufacturing’s specific needs. Key components of the solution included:

  • Production Automation: Automated the production scheduling and monitoring processes, ensuring optimal use of resources and minimizing downtime.
  • Inventory Management: Integrated real-time inventory tracking to manage raw materials and finished goods efficiently, reducing waste and ensuring timely availability of materials.
  • Quality Control Module: Established a robust quality control system that tracks production data, monitors compliance with quality standards, and generates detailed reports for continuous improvement.
  • Data Analytics: Provided real-time data analytics and reporting tools to support informed decision-making and strategic planning.

Results:

  • Enhanced Operational Efficiency: Automation of production and inventory processes reduced manual errors and improved overall efficiency by 40%. The streamlined operations allowed TPP to meet production targets consistently and on time.
  • Real-Time Insights: Access to real-time data enabled better resource management and quicker response to production issues. This visibility helped TPP to optimize production schedules and improve order fulfillment rates.
  • Improved Quality Control: The quality control module ensured that all PRC pipes met the high standards set by Tokai Hume Pipe Co., Ltd. This resulted in a 20% reduction in quality-related issues and enhanced customer satisfaction.
  • Strategic Growth: With efficient operations and reliable data, TPP Manufacturing could focus on strategic growth initiatives, including exploring new markets and expanding their product line.

Conclusion: By implementing our ERP solution, TPP Manufacturing Sdn Bhd successfully automated their operations, resulting in significant efficiency gains and improved quality control. The integration of real-time data analytics and robust inventory management enabled TPP to maintain their high standards of production while positioning themselves for future growth.