How A2R Tooling scales manufacturing operations with ERP

The firm, which produces high-precision injection mould tooling and plastic components, had built an enviable reputation for its responsiveness and craftsmanship, and counts iconic brand Aston Martin among its customers. 

However, the team knew that meeting the same high standards they scaled up their operations would be difficult if they continued to rely on spreadsheets and other manual processes. 

They needed a modern ERP system that could provide real-time insights and streamline their workflows. While there were plenty of ERPs on the market, not all of them offered the functionality A2R Tooling was looking for. Their research led them to Ridder iQ, ECI’s cloud-based solution, designed for small to mid-sized discrete manufacturers. 

It’s easy to take everyday frustrations for granted, accepting them as ‘part of the job’. What A2R Tooling didn’t realise was that its long-standing problems – highlighted below – could be solved with Ridder iQ.

Using spreadsheets to manage stock was not only time-consuming, it left the team in a precarious position. The system often broke down when someone accidentally locked a file, so they had no choice but to revert to pen and paper. 

It wasn’t exactly sustainable from a cost and time perspective, even in the short-term let alone as the company took on new orders. Stock shortages were a persistent problem for A2R Tooling, and it would often have to use expensive last-minute air freight to ensure customers receive their orders in full. 

How Ridder iQ can help: Using an ERP to store all information in one centrally-accessible location immediately replaces the complex system of spreadsheets that A2R Tooling had built up over the years. Team members won’t be locked out of spreadsheets, nor will they have to trawl through them to find what they need. Instead, they can instantly view available stock in real-time, avoiding delays.

Now plans are underway to introduce mobile scanners for deliveries, enabling them to manage the thousands of parts that go into assemblies. Data captured by the scanners will go straight into Ridder iQ, providing a real-time view of exactly what stock is available. This will make it easier to proactively manage customers’ orders, once again ensuring there are no stock shortages or delays. 

Information contained in multiple spreadsheets meant the team at A2R didn’t have the visibility they needed to make effective decisions – resulting in potential stock-outs, bottlenecks and delays. These problems would only get worse as the company scaled up production. 

How Ridder iQ can help: Not only is information stored in one location, it is also readily available to all those who need it. The progress of every job can be tracked via live KPI dashboards, so managers can anticipate any problems and take action in plenty of time. They can also keep the senior management team fully informed of orders and how they align with wider business goals. 

Poor visibility wasn’t the only issue facing A2R. Multiple spreadsheets had to be updated manually, and there was always the risk that something could be missed. There was also the potential for information to be recorded inconsistently and/or inaccurately by different people. 

How Ridder iQ can help: Ridder iQ provides a single version of the truth – there is one set of data, in a standard format, which only needs to be updated once. No matter how many parts there are, and how complex the assembly becomes, teams can create a reliable record via a simple drop-down menu. The record contains a full version history, so it’s easier to trace back every part. 

Good inventory management, real-time visibility, and version control will benefit any business but they're non-negotiable if you’re planning the next stage of growth. While you might have got by with spreadsheets until now, an ERP allows you to reduce complexity and scale up confidently – easily taking on new orders, and managing multiple parts, assemblies and suppliers. Good ERPs start to deliver value, in terms of cost and time-savings, almost straightaway. But as with A2R Tooling, they also put you on a strong footing for the future.