"From deployment through customer support, we have been extremely pleased with Paper-Less. Whenever we’ve had questions, someone from Paper-Less has responded quickly with the necessary information. I would highly recommend the Paper-Less system to anyone who is in the market for a similar solution. On a scale of one to ten, Paper-Less definitely rates a ten.”
Scott Kadak, IT Manager
About Schrader International
Founded in 1844, Schrader International invented the industry standard tire valve in 1898, which is still used on all motor vehicles today. In the 1950s, Schrader developed the tubeless tire valve, eliminating the need for inner tubes on car and truck tires. Today, Schrader sells products to two major markets: the automotive original equipment manufacturers, companies that produce parts and components for new motor vehicles, and retailers of replacement parts known as the aftermarket.
The Challenge: Providing Visibility into WIP
With the dominant market share in the automotive sector and as a supplier to every major vehicle manufacturer in the world — including GM, Chrysler, Ford, Hyundai, Mercedes-Benz, BMW, Suzuki, Mitsubishi, Nissan, Subaru, Saab, Volvo, Citron and Peugeot — Schrader was doing most things right. “We have experienced employees,” explains Scott Kadak, IT Manager for Schrader, “and they work hard to keep on top of everything. But the shop floor (WIP) was kind of a black hole — even to our production veterans. Orders were created without start and due dates. Every area kind of did its own thing. We had a lot of silos of information, but people didn’t understand how their efforts impacted the production process. We lacked control and oversight.”
High-End User Acceptance
In 2006, Schrader began working with Paper-Less to deploy their manufacturing execution software system. “We began by setting up Paper-Less in one small area — almost as a proving ground,” says Kadak. “Once employees from other areas saw how easy the system was to use and the assistance it provided, they wanted it set up in their departments, too.”
Experienced Partner
The entire deployment process went smoothly. Kadak continues, “In addition to understanding the system, the Paper-Less consultants we worked with also knew the operations and production side. I think it really helped that the Paper-Less consultants were experienced in all aspects of the manufacturing process.”
Improved Reporting
The Paper-Less system has had a positive impact on every aspect of Schrader’s manufacturing processes, from start to finish. “In the past, we had written paperwork that was then keyed in by a separate clerical staff,” begins Kadak. “There was at least a one-day delay in our transactions reports. Now all labor and production reporting is done in real-time on the shop floor and standardized across all departments throughout the facility.”
Increased Inventory Accuracy
Inventory has become more accurate and timely. “By using Paper-Less, we were able to tie production and inventory together,” says Kadak. “We’ve increased our inventory accuracy by at least 50%. We have more confidence in our inventory numbers. We can rely on them. Our inventory is ‘live.’ If there’s any problem, we can see it quickly and fix it right away.”
An Unintended Benefit
The estimating process has improved as well. “With a better handle on our inventory and streamlined work orders and labor reporting, estimating and pricing has become less complex” notes Kadak. “Our quotes are probably 15% more exact. The process of estimating and pricing has become cleaner and clearer.”
Reduction in Scrap
Kadak also mentioned improvements in scrap reduction. “The Paper-Less system has helped us to reduce our scrap by as much as 40%,” he says. “We have much better visibility. We can see the scrap and immediately address any related quality issues.”
Barcode Labeling
Schrader integrated the Paper-Less Barcode Labeling for the iSeries (PBLSi), into the production management system, as well. “This allowed us to automatically add a barcode label to every order, showing the part number, quantity, who it’s for and the date,” he explains. “The labels have been a big help in identifying and tracking parts and jobs.”
“This has been a huge step forward for us,” summarizes Kadak. “From deployment through customer support, we have been extremely pleased with Paper-Less. Whenever we’ve had questions, someone from Paper-Less has responded quickly with the necessary information. I would highly recommend the Paper-Less system to anyone who is in the market for a similar solution. On a scale of one to ten, Paper-Less definitely rates a ten.”
