Case Study | A custom-made stock management system solves problems at production sites in Thailand and improves work efficiency

There is a strong need to improve the accuracy of stock management and prevent out-of-stock, excess inventory, and delivery errors. However, it is difficult to master the use of a packaged stock management system, and many companies think that the hurdles are high. How to introduce a realistic system based on the current business flow? In response to that proposition, Tomas Tech's stock management system "PEGASUS" is gaining popularity.

This time, we would like to introduce an introduction example at Sanko Mold and Plastics (Thailand) Co., Ltd. (SMPT), which handles the mold business and plastic molding

Operation that makes use of the format used on site

Sanko Mold and Plastics (Thailand) Co., Ltd. (SMPT), established in September 2012 as a wholly owned subsidiary of Sanko Mold (Miyoshi City, Aichi Prefecture), produces plastic resin parts for motorcycles and automobiles. there is number of products handled has steadily increased year by year, and the number of molding machines, which was only 10 five years ago, has increased to 27. Along with this, problems related to inventory management began to swell.

▲ Examples of products and machines in the SMPT factory

“The staff in charge wrote down the inventory numbers on the whiteboard and updated them as needed, but human error was unavoidable. We also made a lot of mistakes. To solve this problem, we introduced Tomas Tech's Stock management system." (Mr. Nakashima, SMPT) The decisive factor for the introduction was the custom-made specifications that allowed the format used by the company to be used as is.

"At first, we were considering the completed software, but it was expensive and we had to match the business process. In that respect, Thomas Tech's system was custom-made. Regarding the inventory management flow and requests After listening to the details and reconciling them many times, we asked them to incorporate the functions they wanted into the software. Because Excel which they are accustomed to using, can be used directly on the program, so the on-site staff feel uncomfortable. No.” (Mr. Nakashima, SMPT)

Significant reduction in errors of delivering products different from the order

The three points of the Tomas Tech system introduced by the company are as follows.

“In our company, it is basic to have stock for 5 days. The order point quantity can be calculated by dividing the PO for each customer and product by the number of working days, but if the inventory is less than 5 days, the alert will be orange, and if it is less than 3 days, the alert will be red, the efficiency of ordering work has been improved. At the time of delivery, the information about what and how much should be delivered today and where the product is located is displayed. There is no mistake because it is good. All of these functions were created through dialogue to prevent problems that occurred on site.” (Mr. Nakashima, SMPT)

▲ Accurately manage location by attaching QR to KANBAN for site work instructions

▲ FIFO (first-in, first-out) is performed smoothly by QR management

It was introduced in September 2021. Although the system has not been completely transferred to the system yet, it is said to be well received by the on-site staff. Above all, it would be a great harvest that the error of delivering a product different from the order has been greatly reduced.

Eventually expand to material management and work-in-progress management

In the future, we will expand the stock management system to material management and work-in-process management, eliminate the risk of out-of-stock, and consider inventory management with appropriate inventory. Furthermore, in the near future we plan to introduce a stock management system for materials and parts at factories operating in Vietnam. Unlike Thailand, the lead time for materials is long and the amount of one order is very large, so there are many issues to consider. We are in the process of preparing for the introduction of

Currently, the number of items handled by the company is about 300 SKU. The number of items is expected to increase further due to the increase in new business partners.

"As the number of items increases, the importance of a stock management system will increase more and more. A system is meaningless unless it can be used easily and quickly by anyone and can be continued. Simple is the best. I am also grateful for their flexibility in making fine adjustments, such as changing the program of the system. I would like to continue to make adjustments while operating the system, and develop it into a system that can be used by anyone in the field." (SMPT Mr. Nakashima )

Tomas Tech's inventory management system that aims to improve work efficiency and work accuracy while making use of the on-site work flow. What makes this possible is the friendly and meticulous responsiveness of being close to the customer, accurately picking up the problems they are facing and trying to solve them.

【Coverage cooperation】
Thai subsidiary of Sanko Mold Co., Ltd. (Headquarters: Miyoshi City, Aichi Prefecture). Established in 2012, it manufactures molds, mold parts, and plastic injection molded parts at its own factory in the Amata City Rayong Industr ial Park.

▲ From the left, Mr. Nozaki from Tomas Tech, Mr. Nakashima from SMPT

Sanko Mold and Plastics (Thailand) Co.,Ltd.
Kunihiro Nakashima
Managing Director

TOMAS TECH CO., LTD.
Ryo Nozaki
CEO

If you are looking for a stock management system for the manufacturing industry in Thailand, or if you are considering building or installing a system, please contact us using the form below.