A multi-site, U.S. fabricator had a goal to improve efficiency, productivity and accuracy in material management, including pipe spools and modules. They launched a company-wide, phased approach to deploy Inspections Loop Material Readiness, automating reporting and enabling visibility into internal and external progress communications.
With a goal of proactive and predictive material and process control, the fabricator digitized data collection with RFID tags, barcode labels and mobile hardware, providing unique services to clients with real-time reporting and downstream material tracking. After integrating Loop Material Readiness into their existing scheduling software, enterprise resource planning (ERP) tool and engineering bills of material (BOM), the fabricator set themselves apart from competitors with total visibility into their processes, including enhanced collaboration and communication with the workface planning tools of EPC firms and prime contractors.
The fabricator has three facilities in the eastern U.S. and business units in industrial construction, pipe fabrication, modular fabrication, fire protection and engineering services. With over 800 employees, 8,000 global clients and over 20,000 projects, the fabricator’s mission is to increase productivity while maintaining safety standards.
Pain points in the traditional fabricator workflow
Growth brings growing pains, and as they grew, the fabricator noticed cracks appearing in traditional processes like inventory and shop floor control.
Disparate spreadsheets for inventory
Shop floor control run on disparate spreadsheets
Spreadsheets lacked visibility and consistency, leading to data silos
They needed a resolution that provided visibility and transparency, both internally and externally.
The Goal? Efficiency and Visibility
Solution
Loop Material Readiness worked with the fabricator to develop solutions to improve process productivity, efficiency and accuracy.
Removed paper-based systems
Automated pipe spool status activities
Created a single source for material inventory
United three shops under one tracking/location system, providing material visibility to corporate
Provided client access to material status reports and downstream tracking
Where does Loop Material Readiness fit into their processes?
The fabricator’s scheduling software feeds into the ERP system which sends material information into Loop Material Readiness, which is also populated with engineering BOMs from third parties.
Results
Proactive and predictive material and process control
Key performance indicators and dashboards
Management by exception allows the fabricator to correct issues before they become problems that impact schedule
Mistake-proof processes via digitized data collection and the elimination of paper-based transactions
The fabricator’s Loop Material Readiness deployment across multiple facilities led to efficiency gains and increased process visibility and was made possible by digitized material data collection and a collaborative workspace that adds value upstream.
