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DHApps – comprehensive solution for an international manufacturing company

Industry
Produkcyjna Żywnościowa
System implementation:
Aplikacja dedykowana Comarch ERP XL
Client headquarters
Birma Brazylia Czechy Egipt Hiszpania Holandia Indie Polska Portugalia RPA Serbia Wietnam
Industry
Produkcyjna Żywnościowa
System implementation:
Aplikacja dedykowana Comarch ERP XL
Client headquarters
Birma Brazylia Czechy Egipt Hiszpania Holandia Indie Polska Portugalia RPA Serbia Wietnam
Customer Needs

An international feed manufacturer operating in Brazil, South Africa, Egypt, Serbia, Poland, Czech Republic, Netherlands, Russia, Myanmar, Vietnam, India, Spain and Portugal faced fragmented IT infrastructure: factories operated with disparate systems or no digital infrastructure at all.

To-do Group factories used different IT systems or had no digital infrastructure at all
To-do In some factories ERP covered only selected departments – the rest worked manually or with spreadsheets
To-do Difficulties managing information flow across a group operating in 13 countries on 4 continents
To-do Standardising technology infrastructure across all facilities in 13 countries
To-do Customising the system for feed industry-specific processes and local legal requirements
To-do Providing sophisticated yet intuitive reporting and analytics capabilities
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Challenge
To-do Easier planning and full control of the production process
To-do Customising the system for feed industry-specific processes
To-do Availability of advanced yet easy-to-use reporting and analytics tools supporting decision-making processes to control production profitability, costs and cash flows
To-do Maximising factory performance through automation and integration
To-do Establishing real-time operations across warehouse, sales, production, logistics, HR, accounting and CRM
Solution
1 We deployed ERP software where none existed previously, and developed a dedicated application suite (DH Apps) comprising three interconnected applications serving the entire global organisation.
2 DH Holding (Desktop – Headquarters Level): strategic data management system collecting information from all 13 countries, offering centralised management and data validation before distribution across 4 continents.
3 DH Country (Desktop – Regional Level): second-tier system managing country-level strategic data, ensuring consistency across multiple factories and enabling bidirectional communication between plant systems and headquarters.
Implementation areas
DH Apps package

DH Holding –

desktop software for company headquarters, the highest level of the DH Apps package. It collects information flowing from the entire company. It enables central management of strategic company data (MDM – Master Data Management) and maintaining defined standards across the entire corporation.

Data is appropriately validated, filtered and distributed to company branches in 13 countries on 4 continents. Collected information is displayed in the form of comprehensive reports enabling rapid analysis.

The system allows users to, among other things:

  • manage a global product catalogue
  • view nutritional data related to production
  • manage and control production quality
  • work with reports from aggregated data
  • define business structures
  • distribute and aggregate data within the corporation

 

DH Country –

the second tier in the DH Apps architecture. The main purpose of the application is to manage strategic company data within each country, ensuring consistency between multiple factories.

It is a dedicated desktop system that enables bidirectional communication: with factory systems and the headquarters system. DH Country offers a range of reports from data collected at country level. The system was designed and built to easily integrate with ERP systems from various vendors at the level of records, orders and logistics documents.

The system allows users to, among other things:

  • manage the country-level product catalogue
  • extend the production module adapted to feed industry needs
  • view nutritional data related to production
  • control production and delivery quality
  • work with reports from data originating from multiple factories
  • distribute and aggregate data within the business structure

 

DH Plant –

a dedicated web and mobile application operating at the level of a single factory. The system supports comprehensive management of a factory producing feed or other finished goods according to recipes.

The system helps in areas such as:

  • managing deliveries and shipments
  • picking
  • warehousing
  • industry
  • production
  • conducting quality control
  • quality control
  • workflow
  • electronic document circulation

 

The system contains the following independent modules:
Warehouse module with zone and storage location subdivision.
Production module for recipe-based manufacturing with comprehensive management of the packaging process, product batch settlement and delivery settlement.
Quality control module based on provided quality standards for raw materials and finished goods.
Module for handling vehicle (or other transport) entry and exit.
Integration module with external systems (DHC parent system, PCS, LIMS).
Technologies
Framework used in DH Holding and DH Country for robust desktop application development.
Frontend framework used in DH Plant web application for dynamic factory-level interfaces.
Relational database used across all DH Apps components for structured data management.
Enterprise messaging and containerisation technologies. NServiceBus and RabbitMQ enable reliable communication between distributed system components. Docker provides consistent deployment across multiple international facilities.
Integrations

The system integrates with:

  • Production Control Systems (PCS)
  • Laboratory Information Management Systems (LIMS)
  • Weighbridge equipment
  • External ERP systems from multiple vendors
The system allows users to, among other things:
  • recording purchases/receipts and issues/sales, with weighbridge integration enabling automatic weight registration at production plan receipt,
  • recording production,
  • recording collected samples and laboratory results, managing test results (accepting, rejecting results) and sending to other factories for testing at other locations,
  • grouping, combining samples (multiple silos on a vehicle, several production batches),
  • recording data from external production control systems (PCS),
  • warehouse management – warehouse map with detailed information on goods location,
  • controlling goods batch paths from purchase, through storage and production, to sales,
  • goods identification based on unique barcodes,
  • mobile work used in: production, sales, inventory.
Results
Results

Productivity gains through increased production capacity utilisation, control over processes in all factories with transparent quality test results, centralised data infrastructure with unified reporting to headquarters, real-time access to counterparty data and transaction history, and centralised IT administration with integration to external ERP systems.

“The system has been adapted to our needs and supports management in the areas of production and logistics processes, sales and warehouse management. The implementation also increased the efficiency of the accounting department. Thanks to friendly and advanced Business Intelligence tools, multidimensional reports and analyses are within everyone’s reach, so decision-makers spend less time searching for information and can focus on strategic decisions.” — Reynauld van Rooyen, IT Manager De Heus Feed Ltd.

Selected solutions
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