A global non-profit company working in over 180 countries and territories needed a better way to manage their Dynamics 365 implementation. Their massive 185,000 sq ft print center produced thousands of materials daily. But behind the scenes, they faced serious visibility and efficiency issues.
Challenges
Manual Processes and Limited Integration
Prior to the project, the organization’s plant floor machinery was not integrated with their Microsoft Dynamics ERP system. This resulted in several manual processes for employees, with machine and job performance data only captured sporadically, about every four months. The lack of consistent data collection led to increased machine errors, more frequent breakdowns, and higher material wastage, ultimately causing significant losses in both time and costs.
Real-Time Reporting Limitations
Limited technical integration meant that real-time reporting of print jobs was not feasible. As a result, monitoring daily output and gaining operational insight was challenging. This lack of visibility contributed to inefficiencies in inventory planning, leading to overstocking of some items and shortages of others.
Solutions
JourneyTeam led the Dynamics 365 project for their print division, focusing on manufacturing, supply chain, retail, and eCommerce operations, and continues to provide ongoing support to meet the company’ unique needs.
Impact
At JourneyTeam, we strive to effectively use technology to create a positive, meaningful impact on the world. This project with a non-profit global printer is a prime example, as it harnesses innovative solutions to achieve our goals.
Dan Brown, JourneyTeam’s Practice Director, ERP
Automating Data Collection and Machine Integration
Through collaboration with JourneyTeam, the organization successfully integrated their plant floor machinery with the Dynamics 365 ERP system. This integration enables automatic capture of machine performance metrics throughout the printing process. Machines now report job start and end times, waste produced, and production metrics directly to the ERP system. This automation has resulted in a 20% improvement in overall production time and significant cost savings, as manual data collection is no longer required.
Additionally, the automated system supports proactive machine maintenance by identifying potential issues in real time, replacing the previous quarterly manual checks. This allows for better management and maintenance of equipment, further reducing costs.
Modernizing Operations Through Data
JourneyTeam developed an integration between Dynamics 365 and the production floor, establishing a consistent data collection model. Programmable Logic Controllers (PLCs) gather data, while Human-Machine Interfaces (HMIs) collect inputs from machine operators. Data from both sources is transmitted via Azure, providing real-time information accessible on the printing floor. Operational status is displayed on a large screen, enabling teams to monitor machine performance and respond promptly to issues.
The system allows tracking of printed items, distinguishing between acceptable products and defects, and also supports performance analysis. Key performance indicators (KPIs) were established to identify areas for improvement, enhancing both machine performance and productivity. Integrated data feeds into the ERP system, improving planning for raw materials and resource allocation, and supporting audit inquiries related to material usage and production waste.
Partner with JourneyTeam
The successful integration of Dynamics 365 ERP into the organization’s print operations demonstrates how strategic collaboration can drive meaningful change. By working closely with JourneyTeam, the non-profit was able to realize measurable improvements in efficiency and cost management. This partnership not only addressed immediate operational challenges but also positioned the company for ongoing success as their needs evolve.
If your organization is considering similar improvements or facing challenges with operational visibility and efficiency, JourneyTeam is ready to help. Let’s start a conversation about how JourneyTeam can support your goals and drive lasting results.