"WorkPLAN helps Austrian mold maker to raise productivity through better management"

February 16, 2012 - Sescoi’s WorkPLAN ERP system has enabled Mangel Formenbau GmbH to significantly raise mold making and management efficiency through its simple operation, and powerful software tools, tailored for custom manufacture. The company found WorkPLAN had the flexibility to fit with its working practices, increasing transparency and productivity throughout the organization.

Mangel specializes in the design and manufacture of plastic injection molds at its factory in Roggendorf, Austria. Walter Mangel, founder and CEO explains, “ Our main business is molds for automotive lighting systems. Other sectors include entertainment, household electronics and medical equipment where we can offer industry-specific expertise in the manufacture of plastic parts.” Mangel’s service starts with analysis of plastic flow for the component, mold design, manufacture, first off molded samples and finally test reports for the samples.

The company has a policy of investment in high technology equipment and training to keep it at the leading edge of its industry. Philipp Mangel who is responsible for order processing and customer service says, “ Our investment program distinguishes us from other suppliers. We have invested in five machining centers with linear motors in the last two years and none of our equipment is more than five years old. Furthermore, we have invested in software for plastic flow, mold design and CNC programming including Sescoi’s WorkNC CAD/CAM software, so the next logical step was to install ERP to manage our business administration, planning and production.”

Mangel evaluated three systems and chose WorkPLAN as it was easy to adapt it to the manufacturing processes used by the company, it automatically provided real-time costing analysis and a clear overview of current orders. WorkPLAN controls the complete manufacturing process, quotations can be prepared extremely quickly from historical information and costing can be as detailed or as simplified as suits the individual company. Once an order is placed, the system automatically generates the necessary works orders and keeps track of progress through the workshop, providing warnings for potential delays. The data relating to each job is stored centrally, so it is easy to check costs and progress in real-time and to examine the history of design changes, quality evaluations, delivery and invoicing, providing full traceability.

Philipp Mangel says, “ We were familiar with Sescoi from our use of WorkNC and we were influenced by WorkPLAN references from Injectorplast and Harting. As well as costing analysis and order overview, the software registers staff and machining times. However, the deciding factors were ease of use and cost effectiveness.

Since it was installed, WorkPLAN has become an important part of Mangel’s manufacturing cycle. Philipp Mangel says, “ Our orders have risen steeply since we acquired WorkPLAN, but despite our workload we have been able to install all the important modules with Sescoi’s help. The software manages quotations, order confirmations, production planning, production release and control, delivery notes and invoices. We now have an average lead time for our molds of eight to ten weeks. We have gained significant experience from our daily use of WorkPLAN and its greatest strength is its ease of use.”

WorkPLAN helps the company to maintain its high standards in quality and delivery reliability, two very important factors within its industry. Additionally, the ability to easily customize the software, automatically collect data as a background task and generate professional reports with a few mouse clicks are important benefits for Mangel.

The transparency which WorkPLAN has brought to Mangel has resulted in real cost savings. Philipp Mangel says, “ The greatest economic benefit is time saving in finding quotations, invoices and delivery notes, and in its simple documentation and manufacturing process management. Information about which employee has produced which part and on which machine is instantly available, as is a display of real-time progress, enabling us to act in time to avoid potential delays.”

Walter Mangel particularly likes the way in which WorkPLAN keeps track of frequent mold modifications, which are a common occurrence within the industry. “ WorkPLAN’s non-conformity records are very helpful as they automatically index and document all the changes ensuring that the customer gets up to date information.”

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