Our partner is a leading Bulgarian manufacturer of cables, insulated cords, winding wires and PVC compounds for cable and conductor production. They recognised the opportunity to digitalise their internal workflows in order to increase productivity, reduce error margins and become eligible for more industry certifications. After partnering with Dreamix, they have achieved a complete digital transformation of business-critical processes.
The Story of Our Partner
EMKA is a leading Bulgarian cable and wire manufacturer. The sole manufacturer of round and rectangular copper/aluminium wires with different types of insulation in Bulgaria, the company also distributes to factories in Germany, France, Austria, Hungary, Greece, Latvia, Romania, Serbia and more. With a strong focus on product quality, operational efficiency and safety, EMKA has an over 87-year history of creating and distributing high-quality cables and wires for a diverse range of applications.
The Opportunity
EMKA’s production process involves multiple components, various stringent quality control measures, and spans across multiple shifts and workers. They had a manual, paper-based process in place - but they realised it was time for a better way to track materials, waste, and oversee labor and production. A digital track-and-trace solution would be able to sync with their ERP system, save them money and manhours, and reduce the risk of errors. Equally importantly, certain ISO certifications and customers required them to have well-documented, automated and unified processes to remain compliant.
The Solution
The first thing we did was develop a Manufacturing Execution System (MES) to enable their workers to easily log their hours from strategically placed terminals around the premises. We built the MES from scratch—we used Java Web Frameworks for the back end and Angular for the front end—and we integrated it with the ERP API to enable smooth data exchange in real time between the two systems.
We also created a PostgreSQL database to store all the data. EMKA wanted the system to be hosted on-premise for enhanced security and flexibility, so we designed and built the server’s infrastructure at their location.
The final solution had a host of business-critical features, including:
- Employee and role management: Streamlined user access and permissions to improve security and reduce the risk of unauthorized access.
- Manual data input software and hardware: Workers can easily enter precise data into the system, which reduces errors and improves data integrity.
- Traceability: Internal barcode and QR code printing and scanning, allowing for each component’s history to be tracked - a crucial part of ISO certification.
- Track and Trace: Transparency and accountability across the entire supply chain helps reduce the risk of disruptions
- Manufacturing ERP and Warehouse integration: Real-time synchronisation between manufacturing and warehouse operations for improved inventory accuracy and production planning.
- Data Analytics: Actionable insights into performance and efficiency to enhance data-driven decision-making.
The Results
As a result of our work together, EMKA received a Manufacturing Execution System that’s fully integrated into their ERP and allows for increased oversight into labor units, production, and waste. The system has brought benefits such as:
- Increased productivity
- Decreased defective products
- Increase predictability in manufacturing
- Decrease in lost items
- Clear and transparent internal supply chain
- Faster shipping of products
- A more clear cost structure of items
- Evidence for material, energy and labor consumption
In short, our collaboration has resulted in a successful digital transformation for the leading manufacturer and helped them achieve their workflow optimisation goals. We at Dreamix are proud to have been part of their transformation journey and look forward to providing further value to our partner.
