Speciality Chemicals: Production & Productivity Optimised

Chemicals Warehouse Process improvement

Stock control, fleet productivity and production processes optimised for speciality chemicals business

 

Speciality chemicals supplier Cod Beck Blenders is using the Principal Logistics Technologies (Chess Logistics Technology) ProWMS Warehouse Management System to oversee key stock control processes at its facility in North Yorkshire. The application has evolved over a number of years to integrate multiple functions and create a highly specialised solution that has helped to improve on-site efficiency, productivity and performance.
 
 

“We use Empirica for stock husbandry,” says Nigel Jameson of Cod Beck Blenders. “We can identify where stock is and more importantly make sure stock is right for the customer. This was our main reason for choosing it and Empirica does this very well.”

 
 
Cod Beck Blenders offers a wide range of toll and contract manufacturing services to international blue-chip clients within the pharmaceutical, agricultural, agrochemical, horticultural, and fine chemical industries. As a trusted partner providing an integrated service for ‘own label’ products the business has grown significantly since its formation in 1988. Today it operates from a purpose-built eight-acre site in Thirsk, North Yorkshire which includes six dedicated units that enable a full range of services including blending, packing, and specialised chemical drying of powders and liquids.

Warehouse Management technology upscaled for business growth

The company is a long-term adopter of warehouse management system (WMS) technology originally developed by Principal Logistics Technoligies, and recognised that the underlying capabilities could be applied to other parts of its business. As the business grew, instead of continuing development of the original system, which it still uses in some of its warehouse operations, it decided that the newer ProWMS was more suited to its evolving requirements which included stock husbandry as well as conventional warehouse management. This advanced application is based on a core covering all key WMS functions which can be supplemented by various configurable modules to create what is effectively an entirely bespoke solution.
 

“Out of the box it works perfectly but we wanted to integrate different functions without putting in other systems,” says Nigel Jameson. “It’s the flexibility of the system to add additional packages or modules. We wanted one system that we put it in once.”

Warehouse production process improvement

ProWMS is used is to support Cod Beck Blenders’ production process. Products are typically prepared by combining various stock chemicals to create blends to customers’ unique specifications. These combinations – and hence the production process – can be complex and it is essential for smooth and efficient operations to track not just the raw ingredients but also the finished products as they enter and leave various parts of the facility.
 

 
Incoming orders are processed by the sales team. If the product is available, it can be scheduled for delivery but if not, it must be blended. Inbound deliveries of the required stock chemicals are checked as they arrive and details logged onto ProWMS before being transferred to storage until needed. ProWMS will only allow the job to start when all required stock is available and can instigate orders if more is required. This function has helped streamline production schedules and is one of the many adaptations of the application.

When production starts, the system issues instructions to truck mounted RF terminals to transfer stock from the stores to the blending area. Work can only start when all stock is in position. Cod Beck Blenders works to exacting standards and it is important to add the precise amount of each component to create the finished product. These amounts are tracked using ProWMS so that the company has an accurate and ongoing record of how much stock has been used and remains available – red-yellow-green coding provides a visual cue on admin screens.

A robust production process adhering to exacting standards ensures that the
precise amount of each component is added to create the finished product.
 

Chemicals stock usage optimised

When the process is complete, ProWMS asks if any remaining stock should be retained in production or returned to stores. If the amount falls below predetermined levels, the WMS will point this out and the stock can be written off. When returning items to store it generates new labels with updated weights and other information. This function, another bespoke development, prevents stock sitting in limbo in production areas, enables a smoother materials flow, and helps maintain a real-time overview of stock held.

Managing stock for manufacturing like this is inherently more complex than traditional warehousing or distribution. Inevitable changes in demands and requirements can lead to new requirements for features that cannot always be foreseen. There have also been occasions when the company anticipated a requirement, introduced a solution, and then decided a different feature would improve performance.
 

“It’s heavily integrated with our business and the way we work,” says Nigel Jameson. “If we get a customer that says they want us to do something in a particular way, we ask can we get the system to do it? We’ve never been unable to do something we want. But if we put it in and it doesn’t work, we will change it.”

 
All of this helps to explain why there have been over 30 modifications to the core system, including some relatively major changes. One example is the ability to track and manage the assays which detail the precise composition of many speciality chemicals. Tracking a single pack of stock is relatively easy but seemingly identical packs can have different assays. If material from multiple packs is used to create a new product its resulting assay can only be determined if the precise assay and amount of each original constituent is known.
 

“We needed a way of logging live data from each bag which was quite challenging and difficult to test, but we worked with Principal to get it right.” Nigel Jameson.

Load bay management & fleet productivity improvements

Another modification changed the way ProWMS manages onsite stock movements. Previously, dedicated trucks worked in each area of the facility and followed instructions issued to them alone by the system. If drivers were busy on other duties the instruction could be delayed before the movement was executed. Also, trucks working in one part of the facility could be busy when those in other areas were idle.

The system was modified so that each instruction is sent to all trucks. Drivers of any permitted truck can complete any handling task in any part of the facility. They scan a pallet and the system tells them where it needs to be. Once the movement is completed and confirmed the task is removed from all screens. Similarly, trucks in quiet areas can be sent to work in the busier sections. This has increased flexibility and efficiency across the site and trucks are now rarely seen moving without something on their forks. Tasks are generally completed more quickly which has improved fleet productivity but also means that production processes are more efficient because stock becomes available for blending or despatch sooner.
 

Online stock movement optimised
 

“Before we knew it trucks were working all around the site. But this is not just about the trucks – it keeps the factory running.” Nigel Jameson.

 
The finished product is labelled and checked. A picture of how the pallet should look is added to enable a quick and easy visual check. This is particularly useful for orders destined for export because people across the supply chain might not understand textual information even though details can be verified using the order’s barcode.
 

 
Products are stored until required by customers who can request a complete batch or draw off smaller amounts. First-in, first-out rotation ensures efficient inventory management. Orders are checked several times before despatch and only released for delivery following a quality control inspection. Items are removed from the system once they have been despatched.
 

Seamless integration into new warehouse

Business growth led Cod Beck Blenders to build an additional warehouse to accommodate more storage. Part of the project involved incorporating WMS into the new building. “This was a brand new building with a better specification”, says Nigel Jameson. “ProWMS went in absolutely seamlessly.”
 

“Chess gave us everything we asked for. With Empirica we can say ‘we need this, can you put it in’ and they say ‘yes, we can.’ We have made so many changes that it differs from the core product so much.” Nigel Jameson.

 
Recently Cod Beck Blenders has been upgrading the truck-mounted RF terminals to colour touchscreen models that are easier to read in the low-light warehouse environment. The ProWMS-driven on-screen displays have been revised to incorporate more information and take advantage of the terminals’ capabilities. The company anticipates this will deliver new performance boosts.