Process change: Infor and Synergy Resources visualize lean ERP deployment for Graphicast

A lean scheduling solution deployment has expanded production capacity and enabled business growth for a N.H.-based molding casting specialist.


Jaffrey, N.H.-based Graphicast uses graphite mold casting technology to make precision metal parts. The company had been producing 12 inventory turns per year, which was impressive, but customers were given 16-week lead times. In addition, management didn’t see a way to take on new business without investing in capital equipment.
Synergy Resources , an ERP solutions and services provider, now reports successful installation of its lean scheduling solution at Graphicast in partnership with Infor, one of the largest developers of business software worldwide.
Graphicast has been using Infor VISUAL ERP since 1999. President Val Zanchuk ran an efficient operation but wanted to increase capacity to continue growing the business. Now, using Infor VISUAL EasyLean, customers incorporate pull-oriented scheduling techniques that allow users to make better decisions, release inventory at optimal times, and smooth production flow.
“We hired Synergy Resources to install and train us on EasyLean, and with their help we were able to cut our lead times in half upon implementation,” says Zanchuk. "And we did it without reducing set-up times or increasing production rates.”
“Infor VISUAL EasyLean will inject parts into the system and releases an order based on whatever lead time you set,” explains Zanchuk. “By doing that, it’s not overburdening operations with many orders in various stages of completeness. EasyLean simplifies the flow of production and provides us with excess capacity.”
Now Graphicast is shipping orders in four weeks, and rush orders can be shipped in days without disrupting the regular production flow.
“For the concept of lean manufacturing to take hold and make an impact on an organization, it requires business process changes that can feel uncomfortable at first. Graphicast’s confidence in the process and their management team’s willingness to embrace change was impressive and played a major role in the success they have achieved so far,” says Darryl Walker, Synergy’s lead consultant for Throughput Improvement Services.

No comments
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Choosing controllers: PLCs, PACs, IPCs, DCS? What's best for your application?; Wireless trends; Design, integration; Manufacturing Day; Product Exclusive
Variable speed drives: Smooth, efficient, electrically quite motion control; Process control upgrades; Mobile intelligence; Product finalists: Vote now; Product Exclusives
Machine design tips: Pneumatic or electric; Software upgrades; Ethernet advantages; Additive manufacturing; Engineering Leaders; Product exclusives: PLC, HMI, IO
This article collection contains the 5 most referenced articles on improving the use of PID.
Learn how Industry 4.0 adds supply chain efficiency, optimizes pricing, improves quality, and more.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

Cyber security cost-efficient for industrial control systems; Extracting full value from operational data; Managing cyber security risks
Drilling for Big Data: Managing the flow of information; Big data drilldown series: Challenge and opportunity; OT to IT: Creating a circle of improvement; Industry loses best workers, again
Pipeline vulnerabilities? Securing hydrocarbon transit; Predictive analytics hit the mainstream; Dirty pipelines decrease flow, production—pig your line; Ensuring pipeline physical and cyber security