Scalable Manufacturing Control Beyond Sage
Gemini Prototyping and Manufacturing Ltd provides prototype parts and manufacturing solutions for sectors including automotive, aerospace, medical and consumer packaging.
As the business expanded across multiple sites, Sage 50 Accounts and Sage Manufacturing could no longer support the level of estimating, shop-floor visibility, audit control, and reporting that Gemini needed.
Qi worked closely with Gemini to migrate from Sage to a more scalable manufacturing solution, reducing duplicate data entry and improving visibility across departments. The result was stronger operational control, better supply chain compliance, and a 60% time-saving in data processing.
The Challenge
Having used Sage Manufacturing and Sage 50 Accounts for a decade to service its prototyping activity, the expansion of their second manufacturing company prompted a wider review into sourcing a software solution that would better meet its operational needs, including:
- A powerful estimating tool for prototype work — Sage Manufacturing estimating functionality was proving insufficient.
- Multiple companies and multi-site location (Gemini had expanded from one to three sites).
- Mixed mode production with Shop Floor Data Collection capabilities.
- The ability to provide a list of jobs by department and enable staff to enter time and quality information for supervisor review in real time.
- A precise audit trail on products (including returns) as a key supplier to a global auto manufacturing group.
- Detailed reporting across multiple sites and varied activities.
- Seamless generation of delivery notes from a central system upon shipping.
- Elimination of external spreadsheets and repeated data entry.
- Secure user profiles and access rights for shop floor staff.
The Solution
The decision to migrate from Sage was not taken lightly. Qi and Gemini worked together to ensure that the move would return the functionality that the business needed immediately and provide the scalability and flexibility required for future optimisation.
Qi spent time with Gemini’s accountants to ensure open lines of communication regarding the format information would be provided in to prepare annual accounts. Deploying limited users ensured that Gemini were not spending resource on excessive user rights, whilst still allowing the shop floor to be visible to the central team.
The Outcome
60% time saving on data processing
Gemini no longer have to enter data multiple times to meet their process requirements and can provide the information required by their global customers and ensure compliance in the supply chain. The time saved on administration is now deployed to more valuable areas of the business.