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Synopsis
A malt producer in Belgium
gains support for expanding its
business and product offerings
when it engages IBM
Web...
Without the proper inventory of a variety of malt, the
company would fail to meet customer expectations.
Traceability was ...
The company can also see exactly where the grains
moved throughout the facility and if they came into
contact with other, ...
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EASI implements an end-to-end enterprise resources planning solution at Mouterij Dingemans

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EASI implements an end-to-end enterprise resources planning solution at Mouterij Dingemans

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EASI implements an end-to-end enterprise resources planning solution at Mouterij Dingemans

  1. 1. Synopsis A malt producer in Belgium gains support for expanding its business and product offerings when it engages IBM WebSphere Developer Services, IBM Global Technology Services - maintenance and technical support and IBM Business Partner Appligen NV (acquired by EASI in 2012) to implement an ERP system based on Appligen’s AAA.ERP software and AAA Financials technology as well as IBM BladeCenter and IBM Power Systems hardware and IBM DB2 and Rational software Customer feedback "The administration and follow- up of the whole production process is running on a very reliable and stable IBM hardware and software platform. Moreover, thanks to this IT solution, I am able to respond swiftly to consumption changes. I can make the right decisions for the production processes as all necessary information is managed in such a way that I can change the production steps on demand" says A. Dingemans, owner and chief executive officer at Mouterij Dingemans. Mouterij Dingemans implements an end- to-end enterprise resource planning solution Since 1875, Mouterij Dingemans NV has produced an extensive range of basic ingredients, such as malt, barley and wheat, for the demanding Belgian and European breweries. The Mouterij Dingemans malting house is geographically centered in the middle of the best barley-growing region, with France, Holland, England and Germany at its doorstep. Malt is germinated grain - usually barley but sometimes wheat and rye - that has been dried in a process known as “malting.” The malting process involves germinating the grains by soaking them in water. After a few days, germination is halted by drying the grains in a hot kiln. After baking, the rootlets are removed, and the remaining product is called malt. The entire process is as quick as a few hours or can last as long as several weeks. In the European agricultural sector, breweries purchase their malts approximately one year in advance. Depending on the sales contract and the barley stock, additional malt is then delivered on request. At purchase, the different types of grains are stored in silos. Assorted varieties are then selected from the silos to produce specific types of malt. Following the malting process, the malt is again stored in silos and delivered to the breweries per the sales contract. Mouterij Dingemans NV is the exclusive Belgian producer of roasted specialty malts, offering an extensive range of basic ingredients including brewers base malts, pale wheat, specialty brewers malts, caramel malt, colored malt and roasted malt. The products are used by Belgian and European brewers to make Pilsen-type beers, as well as Trappist, Abbey and White beers. Business need In the mid 2000s, a food safety crisis prompted the Belgium ministry to establish legislation requiring that all food companies track and trace food products throughout the production process. For Mouterij Dingemans, this meant that each batch of grain had to be traceable 24 hours a day, seven days a week - from the time the grains were purchased to when the malt was delivered to the customer. It also meant the company was now legally required to keep track of which silo each malt was stored in, as well as the farm it came from and the specific plot of land it was grown on. At the time, the company had no traceability or tracking capabilities. Other than referring to error-prone, manually entered data on spreadsheets, the company had no way of knowing which batch of malt went to which brewer or from where the grains originated. As such, if a food safety issue or concern arose, management would be unable to inform customers, leaving the company exposed to liability and legal issues. Inventory was another issue that tied to traceability. To ensure purchase and sales contracts were met, stock levels had to be accurately measured and monitored. Moreover, to guarantee that brewers received the specific type of malt ordered, the company had to track stock levels of malt based on the techniques used in the production process as well as the composition of the malt production lots.
  2. 2. Without the proper inventory of a variety of malt, the company would fail to meet customer expectations. Traceability was now required at two levels: to track the origin of the grain and the malt as it went through the production processes as well as to determine the composition of the grains themselves. To meet traceability requirements and optimize inventory levels, Mouterij Dingemans needed to create a robust information flow as part of its processes - from purchase to production to sales. The ideal solution would enable it to automate and control the outstanding balances between malt sales contracts and the barley purchase contracts as well as to track: - Deliveries, which can be executed in bulk or in sacks - Silos, which can contain several purchases of cereals and several productions of malt - Sale contracts, allowing for revisions as customer needs change - Invoicing, which is based on net weight of freight What Makes it Smarter As food contamination crises increase, more and more government-mandated traceability requirements are being established. After implementing a sophisticated ERP solution with tracking and analysis capabilities, this malt producer was not only able to comply with traceability legislations, but also gained the added benefit of being able to consistently fulfill customer orders for malts with specific compositions. The traceability function tracks the origin, storage silo and production process for each batch of malt. Analysis traces and evaluates each malt batch based on 25 different parameters including structure, weight, diameter, hardness and moisture levels. Combined, they enable the company to locate a specific malt type, consistently duplicate any malting process and then market the malts as new products. This has propelled the company’s growth from a small, regional company to one with customers from around the world. Mouterij Dingemans turned to IBM Business Partner Appligen NV to implement an end-to-end enterprise resource planning solution based on its AAA.ERP software and AAA Financials technology as well as a host of IBM offerings. In addition, various services were provided by IBM WebSphere Developer Services and IBM Global Technology Services - maintenance and technical support. The maintenance and technical support team is providing help-desk, support and upgrade services for the DB2 database software and i operating system. The solution, which is delivered as a Software as a Service (SaaS), was launched in less than three months. It combines all of the company’s applications into a single SaaS solution, delivering real-time information that can be accessed by authorized users at workstations in the production plant during the production process. It also manages key corporate information, including purchase order and invoice processing, sales orders, production planning, production reports with tracing data, lab analyses and recording, inventory control before and after production, composition of deliveries, sales processing and financial information. Information can be stored for years, if necessary, to meet regulations. Real Business Results - Supported growth, enabling the company to expand from a regional to worldwide business - Achieved the ability to duplicate any malting process exactly and consistently, enabling the company to create new malt types if needed - Met food traceability laws and gained more control over grain recalls by being able to track grain from origin to shipment with pinpoint accuracy The new solution has effectively supported the company’s growth, enabling Mouterij Dingemans to expand its product offerings as well as it sales geography. In the past, malts were handcrafted. As a master brewer, the owner would oversee production and manually record information about the grain, the process and the malts. Now, before and after the production process and over the course of several weeks, the company can conduct a variety of tests on each batch of malt, analyzing up to 25 different parameters of the grains including structure, weight, diameter, hardness and moisture levels. This analysis enables the company to exactly and consistently duplicate any malting process, and consequently, recreate malt types, name them and offer them commercially to customers as new products. It also allows the company to fulfill customer requests for orders based on very specific parameters. The resulting insight into and exactness of the production process and products have enabled the company to grow from a small, regional company with local customers to a producer of roasted specialty malts with customers worldwide, including South Africa, the United States and South America. The recording of data also facilitates traceability. The traceability function shows the malt analysis sheets for a given batch that was sold, as well as the production process it went through, from which lot of grains it originated, in which silos the grains where stocked, and from which supplier the grains came. It also meets the requirements of the Belgian federal agency for the Safety of the Food Chain (FASFC). Should management receive notice about a possible grain contamination, the affected products can be found immediately.
  3. 3. The company can also see exactly where the grains moved throughout the facility and if they came into contact with other, noncontaminated grains. Any suspicious malts can be re-analyzed and set aside from production if any anomalies are found, while customers are notified. The solution also helps the company optimize and balance inventory. Before, inventory management was a manual process, and new orders were driven by visually assessing grain and malt levels. Now inventory levels are driven by customer and marketplace demand. The solution provides data about the parameters that make up the best-selling malts types as well as from where the most requested grains originate. With this information, management can increase or decrease stock levels as well as boost production to ensure the most popular malt types are regularly available. Instrumented - The solution is delivered as a SaaS. Real-time information is available to workers throughout the facility at their workstations. Interconnected - The solution combines all of the company’s applications into a single SaaS solution that can then be accessed by authorized users at workstations in the production plant during the production process. Intelligent - The solution can analyze and record up to 25 different parameters for each batch of malt, such as humidity levels, weight, diameter and hardness. This enables the company to duplicate and recreate malt types with extreme accuracy, resulting in company growth and new product offerings. Analysis also allows the company to comply with Belgium food traceability mandates. Analysis shows the production process that each batch of grain went through, from which lot the grains originated, in which silos the grains where stocked, and from which supplier the grains came. Copyright © EASI. All rights reserved Website: www.easi.net Mail: info@easi.net Blog: blog.easi.net Tel. - EASI Nijvel: +32 67 28 10 00 - EASI Mechelen: +32 15 28 75 00 - EASI Luxemburg: +352 26 18 58 11 - EASI Frankrijk: +33 1 72 75 73 89 Please Recycle

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