Company

Name: IBEMA

Locations: Turvo, PR,

Brazil.

Industry: cardboard

paper

Annual production:

108,000 tons/year

ERP System: Microsoft

Dynamics AX.

Web site:

www.ibema.com.br

CASE STUDY - At a glance

Objectives

Gain real-time visibility of the

production throughout the company

and the converters.

Improve customer service and

despatch date predictability.

Improve stock management, going

from a Make-to-Order (MTO) model

to a Make-to-Stock (MTS) model,

promoting trim from stock to improve

customer service.

Gain the ability to react swiftly to

changes, in orders or runs, enabling

the planner to re-schedule on a daily

basis.

Give the Commercial Department

visibility over the production planning.

Implemented Solutions

The project was divided in two phases. For

the first one, the solutions implemented

were:

GreyconMill, as shop-flor execution system

for all the converters.

opt-Studio, as scheduling solution for

Ibema and all the converters.

WebReports, to access the scheduler data

in real-time, from any browser.

Integration with Microsoft Dynamics AX

Implementation time: 11 months

(including a pause of 3 months due to

the Microsoft Dynamics AX

Implementation)

Specialists in optimised production planning & scheduling

Copyright 2002-2009 Greycon Ltd. Registered in England No. 1861647. Registered office at 7 Calico House, Plantation Wharf, York Road, Battersea, London

SW11 3TN. VAT Registration No. 422 3242 00.

Last Update 10 May 2013 www.greycon.com

“Greycon was a true partner for us, they were always open to listen to our needs, even if that implied changes in the project’s scope. We felt very comfortable working with them”

Clécio Chiamulera COO and Project Sponsor

Ibema is a company dedicated to manufacturing folding boxboard paper from virgin fibber. The plant has installed capacity for 108,000 tons/year, making Ibema Brazil’s 3rd largest manufacturer.

Key Benefits

Visibility for PCP from all the four

converters.

Better forecasting of customer delivery

date.

Reduction in late orders.

Fast reaction to machine stops and

order changes.

Better communication between the

commercial area and production area:

subjective discussions decreased.

Proactivity and easiness to act against

unplanned events.

Real-time visibility of the production

schedule for the Commercial Department,

allowing them to know exactly how much

room there is for new orders in each run.

Next Steps

Ibema will continue to improve its

internal processes implementing the

second phase of the project which

includes:

DSO (Demand-Stock Otpimization),

a proprietary algorithm developed by

Greycon to optimize stock levels,

customer service and machine

productivity.

ATP/CTP (Availability to Promise/

Capability to Promise)

DSO will allow Ibema to produce stock

more intelligently, keeping stock level

of sellable material (directly from stock

or through conversion).

Copyright 2002-2009 Greycon Ltd. Registered in England No. 1861647. Registered office at 7 Calico House, Plantation Wharf, York Road, Battersea, London

SW11 3TN. VAT Registration No. 422 3242 00.

“We control our converters on a daily basis, acting when they do not produce what

we planned”.

“Having better visibility we can now easily react when a machine breaks down and we can report the impact this is going to have on order lateness” “We use the estimated despatch date from opt-Studio and we publish this to customers to inform the expected day of delivery, we are getting better results now and the promised dates are earlier”

Gabriel Freire

PCP Coorinator and Project Leader

Last Update 15 February 2013 www.greycon.com

“Now our sales force has real-time production information and we can provide a

better customer service. Further more, this swift communication reinforces the teamwork from Production and Commercial areas”.

Jorge Luiz Grandi Commercial Director