To be competitive in the market and maintain high productivity standards, a crucial aspect companies must consider is the correct and effective management of production. Having cutting-edge tools, specialized know-how, and innovative technologies to organize processes efficiently are key elements to increasing productivity and efficiency.
For this reason, Packstyle chose Omnys and Amazon Web Services (AWS) to create a modular and scalable platform adaptable to its specialized systems. This solution allowed them to double production by optimizing plant use, reduce order processing times, and provided employees the ability to access data to better understand customer needs.
Client
Packstyle is a young Italian company founded in 2020 and is the first Digital Pouch Factory in Europe. It offers the ability to customize its packaging by choosing from various types of food pouches, with different sizes and finishes, fully customizable, and the production chain consists of several stages, with very diverse orders.
Challenge
The client turned to Omnys because they needed to automate the manual processing of orders and have a user-friendly interface that would allow staff to manage them efficiently via tablet, improving the understanding of their customers' needs.
In fact, the company was receiving online orders, which were then processed manually. This was too complex a process for a business model based on fast delivery of multiple orders. Orders were transferred from the website to a spreadsheet, manually reorganized, printed, and sent to the production department; a procedure that inevitably could lead to inaccuracies in fulfillment.
Services Used
The automation of processes was the main challenge for Omnys, to eliminate errors caused by manual management. To do this, it was necessary to first understand the existing systems.
"The Omnys team was on-site, observing our work, helping us improve various stages of the production process,” says Nicoletta Garbo, CEO of Packstyle.
After an initial analysis, Omnys designed and implemented an extremely modular ERP platform, based on AWS (using AWS Lambda Function for processing certain SQS processes). This system is capable of controlling the complex production chain, from order and print file arrival to the dispatch of the finished product (including print file modification, lamination, cutting, etc.). A custom-designed architecture developed specifically for the client's needs, such as the ability to track the materials used to make the packaging.
After designing and developing the ERP platform, Omnys built the MES (Manufacturing Execution System), entirely on AWS cloud architecture, allowing the client to manage production flows continuously.
Additionally, the infrastructure utilizes various AWS services for security, including: AWS WAF as a firewall for web applications, AWS Shield for DDoS attack protection, and Amazon GuardDuty for threat detection. AWS Backup is used for data protection and centrally managed, while data is stored on Amazon Aurora, which offers high performance and availability with full MySQL compatibility.
Results Achieved
The new platform, created by Omnys, enabled Packstyle to increase production from 20,000 units per shift to 60,000, with a 200% increase. The company now has a complete view of each stage of production, allowing them to make accurate forecasts to better plan inventory and supplies.
Employees can quickly see what each customer has purchased, along with complete history, product types, and average order value. This data then allows management to have more in-depth analysis to make forecasts, reports on past performance, and understand the different sectors using this type of product, improving their offers and maintaining a 35% annual growth record.
Following these results, Nicoletta Garbo added: "We really know our customers. We can create specific solutions for every sector and for anything: from supplements to pet products."
Furthermore, orders now move from e-commerce to production systems in 10 seconds, with no human intervention, achieving a 94% reduction in processing time (previously, it took 3 minutes). After payment and graphic approval, the order is immediately ready to be produced.
Finally, the lead time options, which were previously 20, 10, or 6 days, have been reduced to 10, 7, or 4 days, thanks to the speed and accuracy gained, with a 30-50% improvement in delivery times.
The success of this project led to a strong partnership between Omnys and Packstyle; the two companies continue to work together to develop and improve the platform and website.
