C. Brewer Leverages EnterpriseIQ ERP and Manufacturing Software to
Take their World-Class company into the Twenty-First Century

Charles Brewer. Jr., a second-generation mold maker, built a business on the tenets of uncompromising quality, indispensable trust and better-than-prompt delivery. Today these beliefs have never been more relevant for his sons, Charles III and Michael Brewer, as they leverage advanced technology to take their world-class company into the twenty-first century.

Anaheim, Calif.- based C. Brewer Co. specializes in precision plastic injection molding for the electronics, biomedical, medical device and computer industries. The brothers continue to put world-class standards above all else, an approach that enables the company to deliver time-crucial products to companies on four continents. This gold standard began when Charles Brewer Jr. started the company in 1966 and continues today leveraging trust as a critical factor that connects the business with its customers. Customers trust the company to deliver high quality products, on time and on cost. Trust is a critical thread that connects the business internally as well. Chuck and Michael Brewer trust each other to run the business their father started and trust their employees to have the same attitude they do. Today, C. Brewer operates two facilities which encompass more than 100,000 square feet, has more than 50 machines and nearly 300 skilled workers, giving the company complete control over the production process and turnaround capabilities.

When it comes to business decisions, the Brewers trust their data to give them an accurate picture of their orders, production and overall business. The Brewers apply the need for world-class standards to their data quality as well, and nearly 12 years ago, C. Brewer Co. turned to IQMS and EnterpriseIQ to implement an ERP system that delivers trustworthy data.

C. Brewer relies on data integrity to develop key business goals:

• grow through acquisition
• improve production throughput
• better manage inventory through automation
• reduce head count where possible

Data Infrastructure Supports Business Objectives

Designed to add business intelligence to the manufacturing enterprise, EnterpriseIQ uses the latest technological advances to deliver the industry's most comprehensive single-source single database ERP system. EnterpriseIQ does not rely on third-party interfaces to achieve its broad range of functionality. Instead. IQMS uses a single source database in an easy-to-manage, cost-effective environment, powered by Oracle®, the world's number one database. The single database solution provides value in data visibility, reduces interface customization and provides a smooth path for upgrading.

As part of the EnterpriseIQ implementation, C. Brewer Co. developed a list of needed functionality, then added key modules to the system to support their overall information and enterprise goals. In addition to the base system, C. Brewer added RealTime Production Monitoring, Preventative Maintenance, Warehouse Management, Quality, Forecasting, Payroll and Time & Attendance.

C. Brewer began using EnterpriseIQ DOS version in 1993 and moved to the Windows platform in 1999. Prior to 1993, the company used a combination of computerized and manual systems but these lacked a connected interface and were not efficient. Designed for high volume, repetitive manufacturing environments, EnterpriseIQ provided the company with seamless access to information and was readily accepted by employees and customers.

In 2004, C. Brewer acquired a manufacturing company that would expand its capability and add new customers to the company's long-term profitability. C. Brewer was able to leverage procedures and experienced EnterpriseIQ users to quickly bring the new facility up to the company's high standard of operating performance.

Today, C. Brewer's EnterpriseIQ implementation now includes 22 users at two plants with 50 machines connected to RealTime and wireless Warehouse Management scanners.

Real Information, Real Results

For manufacturers like C. Brewer, EnterpriseIQ's RealTime Production Management system provides a true execution solution for implementing lean strategies. RealTime gives manufacturers the substantial capacity to reduce waste and optimize production with verifiable results.

C. Brewer connects 50 machines at two plants to EnterpriseIQ's RealTime system, collects production data a at the machine level and feeds it into the system. Using RealTime, management and shop floor supervisors can see exactly how each machine is performing at any given time.

RealTime At Work

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On a job by job basis, C. Brewer reaps significant benefits from this exacting information. The company uses RealTime to:

• Monitor total cycle times for each job to track progress and determine exact completion time.
• Use historical data, by job and by machine from monitored cycled times, to maximize the scheduling of future jobs.
• Monitor rejects by machine and by tool to make improvements.
• Improve production reporting through.
• Reduce manual data entry and improve data quality in the system.
• Cross production information with preventative maintenance module to schedule maintenance inspections and updates.
• Collect data by work order, part number to improve inventory.
• Print barcode labels for improved inventory tracking.

C. Brewer Co. also utilizes a RealTime connection on a sonic welder, which uses high frequency vibration to generate heat. Each cycle on the sonic welder fuses two pieces of plastic together, which is considerably different than a stamping or injection machine outcome. The result is improved accuracy of the sonic welder's production, which is contributing to better scheduling and enhanced profitability for these types of jobs.

Preventative Maintenance Improves Shop Performance

C. Brewer uses the EnterpriseIQ Preventative Maintenance module to track machine use vs. job cost information and to schedule maintenance based on machine usage. These schedules allow the company to budget for maintenance expenses and extend the life of both tools and machines. This module has integrated links to the overall system that support C. Brewer's long term planning.

Quoting and Accounting Close the Loop

Like any growing company, C. Brewer is constantly quoting jobs for both new and existing customers. The EnterpriseIQ Quoting module enables the company to quickly and easily convert quotes to BOMs, expediting the process of adding new jobs to the system. The company compares standard cost estimates against actual to monitor performance and profitability. In fact, C. Brewer uses IQAlert, a customizable notification tool, to identify quotes and BOMs with missing standard costs. If sales personnel do not complete this information, IQAlert informs the appropriate people to stop job progress until details are provided. This prevents jobs from moving forward without accounting for profitability while maintaining data integrity for the entire system.

Using the Accounting module, C. Brewer has automated the invoicing process, a considerable time savings. Payables are also posted directly against PO's making it clear what has been paid. This simplified information match-up allows the company to do cost variance reports and analyze unexpected costs. These reports provide valuable insight in the production costs and other overhead expenditures that are not inline with budget forecasts.

Both the quoting and accounting modules give C. Brewer the tools to close the information loop on various procedures. This end-to-end information process has become critical to streamlining operations and enhancing profitability by reducing or eliminating the variances and waste.

Forecasting from a Customer Perspective

C. Brewer uses the EnterpriseIQ Forecasting module to track the forecasting plans of their customers. By combing vendor managed inventory (VMI) process with customer forecast data, C. Brewer can manage production and shipments to provide customers with what they need, when they need it. The forecast plans allow C. Brewer to set an in-house stock level and produce parts to that specification. Then the company uses IQAlert to notify customers of what has been shipped and what is available. By automating this communications process, the company has improved customer relationships and streamlined production.

Since this information is electronically populated throughout the entire system, C. Brewer has been able to centralize purchasing for both facilities, reducing the department to a single employee.

Results are More than Bottom-Line

Impressed by the wide scope of EnterpriseIQ's business functionality, C. Brewer has built its improvement plans around the data infrastructure EnterpriseIQ provides. The system has enabled C. Brewer to achieve significant operational efficiencies. C. Brewer plans to leverage the information as a way to eliminate anything that doesn't add value to their products.

This single-minded focus has been the foundation of the company from the beginning and leveraging technology such as EnterpriseIQ will take C. Brewer Co successfully into the future.