12 Months to 100% Digitalization: MES and WMS System Implementation at a Leading Gate and Ramp Manufacturer

Published: 25 listopada 2025

About the Client

One of the largest Polish manufacturers of garage and industrial gates, doors, and loading ramps. Annually, they produce thousands of individually configured finished goods, with Bills of Materials (BOMs) containing up to several hundred items (steel sheets, steel and aluminum profiles, screws, automation, paint coatings, seals, etc.).

Key Challenges Before Implementation

* Paper-Based Operations: 100% of production orders and reports were managed in paper form.

* Data Inaccuracy: Outdated material specifications (BOMs) leading to assembly errors and an increase in complaints/returns.

* Lack of Access: No access to up-to-date technical drawings and instructions at workstations.

* Delayed Reporting: Production progress reporting lagged by up to several days, preventing real-time reaction.

* Manual Inventory: Manual management of the materials and semi-finished goods warehouse.

Scope of the Implemented MES System

A comprehensive MES + WMS class system implemented for 50–100 users in production and the warehouse.

Key Modules and Features:

* Advanced Planning and Scheduling (APS System)

* Production Orders with a full execution path and status tracking.

* Full WMS System (receipts, issues, reservations, transfers).

* Real-time Registration of actual material and finished goods consumption.

* Digital BOM with a library of photos and assembly instructions.

* Large, Dedicated Production Kiosks at every workstation, from the welding area, through laser cutters and the paint shop, to assembly and the warehouse.

* Central User and Authorization Management.

* Advanced Reports available in real-time.

Results After 12 Months of Operation

* 100% Elimination of paper documentation on the production floor.

* Reporting Time shortened from several days to mere seconds.

* Instant Access: Employees have immediate access to current drawings, BOMs, and instructional photos directly on the kiosks.

* Full Traceability and control of every component, from a screw to the finished product.

* Performance and work progress reports available online 24/7.

“This was one of the most challenging MES projects we have carried out in recent years. Ramp production involves hundreds of components, fully individualized orders, and several parallel technological lines. We managed to 100% digitize the entire process, starting from the welding shop, through laser cutters and the paint shop, up to final assembly and the finished goods warehouse. Today, the client has full control over production, the warehouse, and, most importantly, the actual costs of every single order.” - Łukasz Russak, MES System Designer

Summary

Do you want to achieve exactly the same results in your manufacturing company?