Rubber-based seals
Integrated ERP system for watertight processes
Rubber-based seals are used in window frames and escalators. They are also a must in tunnel projects to prevent water damage. Sealable, a specialist in sealing and insulation solutions, relies on an ERP system from Pro Alpha, which covers everything from sales to order processing, production planning, warehousing and shipping.
It's a nightmare for cyclists in the city: getting their tires caught in a streetcar track. To prevent such dangers, the company Sealable has developed an award-winning solution: the bicycle-safe track. However, the Thuringian company's rubber-based applications are not only used in the rail sector. The company is also a proven specialist in tunnel construction. Many of the seals used in window frames in commercial and residential properties today also come from Sealable. The Waltershausen site develops, produces, sells and ships these products directly: The entire value chain is bundled here on site. Two sales offices in the USA and France take care of worldwide sales, as do several agents.
There are numerous manufacturers on the international market for sealing technology. And as is usual in the construction industry, most projects are put out to tender. "On the one hand, our customers are extremely price-sensitive, but on the other, they have very high technical requirements. These can only be met with a correspondingly high level of material and application expertise. Because every application scenario requires a very specific rubber compound," says Managing Director Matthias Orth.
The management buy-out from the Datwyler Group in 2020 brought some upheaval for Matthias Orth and his co-managing director Matthias Klug, and it was also necessary to change the ERP system. The solution needed to be suitable for SMEs and cover as many core processes as possible: from sales to order processing, production planning and warehousing to shipping. This was no easy task, as the number of ERP providers in German-speaking countries is in the hundreds. Nevertheless, the Thuringians quickly compiled their shortlist: "We asked for recommendations and then looked at the coverage of the core processes. Although there are many specialists, there are very few that really offer everything integrated," says Sylvia Tischer, ERP Analyst and Manager Sales Support at Sealable. "Pro Alpha was the candidate that mapped our requirements in the simplest, best and most compact way. Much of what we need is already available as standard." This also includes seamless integration of all processes with financial accounting. This close integration, without data transfers via interfaces, quickly separated the wheat from the chaff in the selection process.
Two business models, one ERP system
Sealable is actually two companies in one: the custom-made equipment for international tunnel projects and the track superstructure division are both typical project business in individual production. The situation is completely different for seals, which are made to order for well-known window and door suppliers. They are also developed individually for the respective window or door profile - including tools and special material composition. However, production is then carried out on demand. "For both business models, individual and series production, we map the complete core processes in Pro Alpha," emphasizes Klug.
All processes closely interlinked
A central data hub is needed to ensure that all processes work hand in hand. Alpha ERP takes on this role at Sealable Pro: with its database comprising all modules, flanked by the integrated document management system (DMS) and the flexible workflows. For Sylvia Tischer, this is a real highlight compared to the large corporate solution of the past: "The DMS is really well integrated. The workflows are also very helpful and easy to use."
For example, the exchange of documents with the main supplier of rubber compounds is fully electronic via EDI. In addition to purchasing and materials management, the medium-sized company benefits from integrated batch management: an indispensable element for tracking potential quality defects or complaints. The Thuringians manage the latter via the service module. In addition to the CRM system for sales, Sealable's asset and financial accounting and cost accounting are fully integrated. "The profit and loss statement is a nice extra for us," confirms Tischer.
Production by the meter
It all began more than 200 years ago with the production of fire hoses. Over the last 50 years, the medium-sized company has developed into an expert in elastomer profiles and the processing of various types of rubber. Over 43 patents are currently registered for the company. Eight extrusion lines at Sealable produce permanently in parallel, with another one being added at peak times. If an order requires the joining of profiles to form frames across corners or rings, the rubber profiles produced are also sent to frame production.
Production planning and production data acquisition are handled entirely by Pro Alpha: Sealable specifies the machine capacities and the ERP system then loads the orders itself. The accompanying personnel planning is currently still done manually. At the end of the extrusion lines, the employees report orders completed on PCs. They enter their good quantities, set-up and production times. Every sales employee can see the status of their customers' orders in the ERP system in real time.
Smooth warehouse processes and shortened stocktaking
Production in Waltershausen basically works according to a supply model. The staff call up the production orders on a PC. By clicking on the parts list, the warehouse receives the request for raw materials for the next order. The automatically generated pick list also informs the warehouse operator directly about the storage location.
With each completed order, the ERP software in turn independently generates the stock transfer orders: The logistics specialists transport the finished products back to their place in the finished goods warehouse - until the order is ready for dispatch. "Pro Alpha also helps us a lot with logistics, I'm thinking in particular of package management," says Tischer.
The new ERP system also saves a lot of time when it comes to stocktaking. At the end of 2022, stocktaking was carried out for the first time in the finished goods warehouse using mobile handheld devices. A test that everyone was excited to see the results of: "Mobile stocktaking saved us a lot of time. Compared to manual recording, we were almost a third faster." Next year, Tischer is also planning to take mobile inventory of raw materials. And she also wants to gradually expand the mobile options in warehouse management.
Everything in view with individual scenarios
A highlight for Sealable users are the so-called scenarios, a special feature of Pro Alpha's ERP system. Instead of having to jump back and forth between different programs or module views, the ERP system shows them all relevant views combined on one screen. This ensures clarity, both in production and in administration. In addition, each employee can create and save their own personal scenarios.
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