“When we heard about Tekenso’s eTrack system, software that provides management with fast, accurate production and manufacturing operational intelligence, we knew immediately that we had to implement the system into our ever-growing company,” said Mischel Frljak, MD of National Stainless Steel Centre, a Gauteng-based stainless steel processor and job shop company.

“The world of the typical metal processor/job-shopper is a highly complex one: a complicated ‘soup’ or mixture of hectic production schedules, timing, stock management, customers’ orders and more. In this environment, several different operational inputs need to happen in order for mission-critical decisions to be made and production promises to be kept: finance, sales, production, logistics, HR, IT (CAD/CAM software, CRM/ERP). Management needs to know the status of everything from sales to pricing, orders outstanding, and how to track work-in-progress on the shop floor in real-time.”

“We had been researching ERP/MRP/PLM/MES systems that were either too big or too costly, not suited to a manufacturing environment, did not provide the information that was promised or is too basic to say it was a complete system like Tekenso’s eTrack system.”

Tekenso’s eTrack production management and manufacturing solution software offers you a centralised control of your whole business

“There are many software packages that help tremendously on either the design or process side and we can’t do without them. But that is far as they go. They are best in class for their function, whether it is an OEM manufacturer’s software or from an independent. In my opinion the concentration has been on this side of manufacturing and not much on software that provides valued information from the beginning to the end. Even the software that runs the machines has been developed to new levels.”

“But as an owner or a manager you want something that will give you valuable information and track the production process at all levels – from order to production to delivery and of course cost and payment.”

“We are a forward-thinking company and one of the largest independently owned stainless steel and alloy metal processing and value adding centres in South Africa. We specialise in stainless steel, duplex, super duplex and high-alloy steel processing. With stainless steel making up 90% of the metal that we process every month we have created a niche and this certainly gives the company many advantages over others, especially as stainless steel processing requires a bit more attention, expertise and technology as compared to carbon steel.”

Through minimising the complexity and number of informational inputs, eTrack has the ability to gather initial information – such as a quote or sales order – and to integrate the required material and drawing office requirements, analysing material and production schedules to ensure similar orders can be grouped and cut together for more efficient and productive processing

“But we are prepared to invest in the processing equipment and supporting activities that will add value to the services we already offer and ultimately to our clients. This is evident by the recent arrival of an automated seam welder for oversize plates, which is an additional service we did not offer previously. We have also added the services of cutting round bar to size up to 350mm diameter to your required length and alloy specification and robotic welding.”

“And towards the end of last year we installed a Trumpf TruLaser 3060 fibre laser with TruDisc 12kW laser source and 6m by 2.5m bed size. This takes us up to eight fibre lasers that have power sources between 4kW and 20kW and can cut up to 50mm.”

“On the power side we have invested in a solar system with a voltage regulator to stabalise the 1 megawatt of clean power that it generates. This keeps the shop running with no dependence on outside power sources.”

“We are now investigating installing an automated bending cell with robot material handling.”

“These are investments in new and existing services and we need to monitor how everything performs, especially in terms of efficiencies and costs.”

“But eTrack is not just about those two informational inputs. It is a lot more.”

Centralised control
“We signed up with Tekenso to become an eTrack proof of concept company just before Covid. Like any software programme used in a manufacturing environment it is not a case of plug and play. The whole system depends on the information you put in. But what it does offer you is a centralised control of your whole business. The system removes complexity from any processing and production environment by creating order and has the ability to track any item(s) throughout your organisation, be that in an office, shop floor, or anywhere where it matters.”

eTrack is a complete management system that incorporates finance, sales, production, logistics, HR and IT (CAD/CAM/nesting software, CRM/ERP)

“You also have to adjust your internal systems accordingly. You can easily make the transition to eTrack if you follow the basics. It is a modular system so you can add various modules when you are ready. It is a complete management system that incorporates finance, sales, production, logistics, HR and IT (CAD/CAM/nesting software, CRM/ERP).”

Plan and rectify
“We love the fact that we can now get our sales and orders correct, which includes costing. We can then plan procurement, routing and processing. We can then continuously track the job while it moves through the shop floor and then give a time of when the component/s are going to be finished. Additionally, we even have the information on how long it takes to process each individual component. This helps tremendously with costing and identifying where we can make improvements.”

The system removes complexity from any processing and production environment by creating order and has the ability to track any item(s) throughout your organisation, be that in an office, shop floor, or anywhere where it matters

“With all this information at our fingertips it is very simple to rectify any process, equipment or human problems. Of the 200 people that we employ 60, or 30% of them, are now using the system. As a result, our efficiency levels are at levels we did not believe we could get to.”

Efficiency
Andrew Poole of Tekenso takes up the conversation: “Businesses require effective management and oversight of various operational inputs from sales to pricing, orders outstanding, and tracking work-in-progress on the shop floor, to ensure the production and delivery of product – on time and within budget – for the end-customer.”

“From quote to invoice eTrack enables the provision of fast, accurate processing and manufacturing operational intelligence.”

Tekenso’s eTrack production management and manufacturing solution software drives National Stainless Steel to new efficiency and control levels

“Through minimising the complexity and number of informational inputs, eTrack has the ability to gather initial information – such as a quote or sales order – and to integrate the required material and drawing office requirements, analysing material and production schedules to ensure similar orders can be grouped and cut together for more efficient and productive processing. eTrack also sets routes and material parameters, and does all-important online, real-time tracking of work-in-progress, thereby empowering companies to keep their production promises to their customers – and to do so in a more efficient and cost-effective way.”

“And this is all in real time.”

Cloud benefits
“The product is web-based, cloud-hosted, modular and in line with contemporary ‘on-demand’ software trends and the data integration demands of the Fourth and Fifth Industrial Revolutions (IR4 and IR5) and the Internet of Things (IoT).”

National Stainless Steel signed up with Tekenso to become an eTrack proof of concept company just before Covid

Offcut management and billing – assets of value
“Because of the availability of qualified information your offcut management and billing then become assets of value. Unnecessary material being sent to the scrap dealer is minimised because you are able to plan better. And this results in more qualified billing – no more guessing. This positively impacts bottom lines, hugely improving customer service and safeguarding customer relationships for repeat business in the future.”

Visibility and tracking
“Always a problem in any metal processing, service centre or production environment. With eTrack, processing and production management becomes a live, dynamic entity, with which companies can interact at will, utilising the robust capabilities of the software to know more – with real-time tracking and reporting – and do more, and do it more productively and more cost-effectively.”

Visibility and tracking is always a problem in any metal processing, service centre or production environment. With eTrack, processing and production management becomes a live, dynamic entity, with which companies can interact at will, utilising the robust capabilities of the software to know more – with real-time tracking and reporting – and do more, and do it more productively and more cost-effectively

Flexibility of integration
“We share our experience and knowledge with you, we keep it simple where possible and visible when complex, integrating all aspects of your business thereby giving you the agility required to solve your challenges. Simplify and optimise your metal processing operation by integrating eTrack into your business.”

“You have to focus on what you do best, because that’s what makes your business successful. My main goal for our company is to further improve your ability to offer your customers high-quality at affordable prices, so they can stay competitive as well.”

For further details contact Andrew Poole on 082 903 4135 / +44 7365 119112, andrew@tekenso.com or visit www.tekenso.com or Manny Da Silva on 083 958 5234