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OMNITROL to increase efficiency at Bay Creek's Missouri plant
Sep '09
After a brief configuration and deployment process, Bay Creek Manufacturing has successfully implemented the OMNITROL Real-Time Manufacturing Visibility solution to increase efficiency and productivity at its main production plant in Mountain View, Missouri. Bay Creek manufactures uniforms such as track suits, and band and cheerleading uniforms for schools and colleges. Every order is unique with respect to quantity, size, style, colors, braid, embroidery, and tackle twill, so that it is not unusual to have well over 15,000 units on the shop-floor on any given day.

"Bay Creek Manufacturing represented a highly complex and customer-driven operational environment," said Sieg Weber, Director of Engineering at Omnitrol Networks. "We are delighted to successfully deploy our unique real-time visibility solution without impacting their operations. It was easy for Bay Creek's personnel to deploy the solution and rapidly accomplish operational efficiencies in their process."

Due to the relatively short order cycle times, Bay Creek Manufacturing required automated collection and integration of real-time operational data to help them identify orders at risk of being late, increase throughput, and make immediate business decisions. The problem was compounded when Bay Creek recently added a third manufacturing plant to meet increasing production requirements. "Manual work-order tracking across all three sites was proving virtually impossible. Bay Creek needed a solution that would provide real-time visibility of not only the Mountain View factory, but eventually across all three facilities," said Sieg Weber, "while keeping the total cost of ownership of the solution as low as possible."

The OMNITROL Real-Time Manufacturing Visibility system is designed to provide automated business intelligence and real-time operational dashboards, scorecards and alerts. The OMNITROL solution is the industry's first fully integrated sensor-based application network that securely integrates business process intelligence with real-time sensors on the shop floor.

Among the benefits Bay Creek Manufacturing cites is complete visibility of the shop-floor. "I can view the complete status of my operations and quickly identify at-risk orders from my desktop", reported Mark Odom, Bay Creek's Vice-President of Manufacturing. "Instead of discovering late orders through missed delivery dates, thanks to the Omnitrol Networks' solution, I am always in the know, and my operations have transformed from a reactive to a pro-active environment where I can address the issues before they escalate into customer problems".

The OMNITROL Real-Time Visibility Manufacturing solution allowed Bay Creek to automatically:

• Enable clients to check the status of their orders in real-time through a web portal
• Accurately track real-time forecasted production against MRP schedules
• Track employee timing and job schedules as they happen
• Reconcile multiple job order pairing

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