Mohawk has appointed Greycon to roll out opt-Studio to its envelope and substrate converting business.
Greycon’s solution was first implemented in Mohawk’s paper manufacturing and converting operations in 1996 and this roll out includes the opt-Studio ATP/CTP (Available to Promise/Capacity to Promise) module to improve customer service levels and on-time delivery.
Mohawk, a fourth generation, family-owned business, makes fine papers and envelopes for the professional design and print communities. Products are developed to support the full range of printing platforms – from letterpress to offset to toner and ink jet. Mohawk distributes to 60 countries around the world and operates three paper machines in two mills in upstate New York and two converting facilities in New York and Ohio, with warehouses in New York, Ohio, California, Washington and the Netherlands.
John Angleson, Senior Vice-President of Supply Chain at Mohawk said: “We recognise the value Greycon’s solution has provided in scheduling visibility, improved customer service and operational efficiency with its finite scheduling optimisation. As a result of the excellent results we experienced with the earlier installations, we decided to invest in the expansion project. We are now able to see aspects of our schedules that we’ve never seen before. Within the first seven days we were able to resolve some critical backlog issues.”
Jay Jordan, Sales Manager for Greycon North America commented: “We are excited to be rolling out opt-Studio in Mohawk to include its envelope and substrate converting business – the Finite Scheduling Model will provide Mohawk with full visibility of production schedules across its operations.”
About Mohawk
Mohawk is North America’s largest privately-owned manufacturer of fine papers and envelopes which are preferred for commercial and digital printing, photo specialties and high-end direct mail. Mohawk fine papers and envelopes include the signature brands Mohawk Superfine® and Strathmore®, as well as proprietary treatments Inxwell® and i-Tone®. With a culture of innovation reaching back to its beginning in 1931, Mohawk is committed to providing materials that help make every printed project more beautiful, effective and memorable.
Mohawk is a fourth-generation, family-owned and operated business based in Cohoes, New York, with global sales and operations located throughout North America, Europe and Asia. For more information, please visit mohawkconnects.com.
Austria’s largest manufacturer of uncoated fine paper, Mondi Neusiedler, has integrated X-Trim to support its planning process. The system was put into operation in the first quarter of 2018.
Erich Leonhartsberger, Head of IT and Logistics at Mondi Neusiedler said: “Changes in product diversity and order structure prompted us to consider adapting existing planning systems. We are pleased to have found a partner with Greycon, with whom we were able to realise our goals in the shortest possible time.“
Michael Kimmeswenger, Project Manager, is also impressed with the results: “We started the project with a one-month test phase in which our planners were given the opportunity to test X-Trim live alongside its daily business. The acceptance was so high that we left the system running as a supportive instrument in the test environment. The roll-out as a productive system proved to be highly satisfactory thanks to the support of all involved.“
“A new record for integrating Greycon’s optimisation solutions into an existing ERP / MES system has been set by the Mondi-Neusiedler’s IT team,” said Markus Rintelen, Manager for DACH / Central Europe at Greycon. “Within two days of integrating the new planning tool into the existing environment, the production team received automated work instructions from X-Trim.”
“We are very pleased with the results. Not only will we save material and storage space, but we have also been able to shorten our business processes, which significantly improves our flexibility,” said Kimmeswenger.
About Mondi Neusiedler
Mondi Neusiedler is part of the Uncoated Fine Paper business unit, a division of the international packaging and paper company Mondi Group. Production focuses on high quality and specialties in the areas of office, printing and packaging applications and takes place at the two sites in Ulmerfeld-Hausmening and Kematen an der Ybbs in Austria.
Mondi is a global leader in packaging and paper, delighting its customers and consumers with innovative and sustainable packaging and paper solutions. Mondi is fully integrated across the packaging and paper value chain – from managing forests and producing pulp, paper and plastic films, to developing and manufacturing effective industrial and consumer packaging solutions. Sustainability is embedded in everything Mondi does. In 2017, Mondi had revenues of €7.10 billion and underlying EBITDA of €1.44 billion.
About Greycon
Greycon is the world’s leading provider of production planning, forecasting, scheduling and manufacturing execution systems that have been designed specifically for roll-based & flat sheet industries. Greycon operates throughout the world. Greycon’s strength is the extensive range of specialist software solutions for Plastic Films & Flexible Packaging, Nonwovens, Metals, Converting, Paper and Board industries supported by powerful optimisation algorithms and a highly experienced team of consultants.
Polímeros y Derivados (PYDSA) is going live with the opt-Studio advanced functionality of block schedule optimisation, to complete the third and last phase of full project implementation.
Overall production capacity at PYDSA has increased continually over recent years necessitating PYDSA to upgrade its planning and monitoring process, optimising the efficiency of their operations and gaining better visibility across all the production lines.
Block schedule optimisation helps resolve issues common in the nonwovens industry, including product complexity, non-constant demand and high switch-over costs, when transitioning from one product to another. opt-Studio, designed specifically for flat-based industries, addresses and resolves issues through optimising the sequence of runs enabling maximum production efficiency, optimal customer service and minimum inventory levels.
Previous phases included the implementation of detailed scheduling on multi-site, multi machine levels, advanced trimming, materials management and tight integration with Microsoft Dynamics (ERP and MES).
Daniel Castro, Planning Manager at PYDSA says: “I am impressed with opt-Studio’s capabilities, both in terms of advanced functionalities and usability, compared with other advanced planning systems I have used previously. Since phase one went live in 2017, improvements have been achieved in sales and operations KPIs, including trim waste reduction, lower inventory levels and shorter lead times.”
Leví Cortizas, Consultant at Greycon says: “It has been a pleasure to work with the PYDSA team. Having completed the implementation of opt-Studio integrated with Microsoft Dynamics GP, it is exciting to witness the tangible benefits achieved. The implementation in parallel of ERP and Greycon solutions was challenging but, with motivated teams and disciplined working, it has been implemented successfully giving PYDSA production efficiency, reduced trim waste, faster and more accurate responses to changes in demand. It has also increased visibility on production efficiency, inventory levels and customer service.”
About Polimeros y Derivados
Polimeros y Derivados (PYDSA) is specialised in nonwovens products with two production facilities in the city of Leon, Guanajuato (Mexico). The products are used for different applications: footwear, recovered leather, foundations, construction, canvas, filtration, automotive and cleaning.
Join thousands of others on the Greycon email list to get access to exclusive content and offers!
If you’re considering using Greycon solutions or just want more information, simply fill in the form below and we will be in touch.
A password will be e-mailed to you.