IBM Case Studies Duas Rodas achieves 80 percent manufacturing productivity gains

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	Duas Rodas achieves 80 percent manufacturing productivity gains IBM

Duas Rodas achieves 80 percent manufacturing productivity gains

IBM

Technology Category	Functional Applications - Enterprise Resource Planning Systems (ERP) Processors & Edge Intelligence - Embedded & Edge Computers Processors & Edge Intelligence - System on a Chip
Applicable Industries	Food & Beverage
Applicable Functions	Discrete Manufacturing Procurement
Use Cases	Manufacturing System Automation Predictive Maintenance
Services	System Integration Training
Challenge	Duas Rodas, a Brazil-based food additives manufacturer, aimed to achieve a sales target of USD 450 million by 2015 by expanding into international markets. However, the company's existing manufacturing assets were at their capacity limits, making it impossible to meet the increasing demand. The company's growth strategy involved significant investments in people, machinery, and technology, but a lack of standardized processes made it challenging to align manufacturing throughput with demand. The business units operated independently, and the lack of integration between client orders, inventory levels, and production planning made it difficult to achieve the necessary manufacturing output. Read More
About Customer	Duas Rodas is one of the largest manufacturers of food and beverage additives in Latin America. Founded in 1925 in Jaraguá do Sul, Brazil, the company has grown significantly and now operates in several countries including Brazil, Argentina, Chile, Colombia, Peru, and Mexico. Duas Rodas employs more than 1,400 people and exports its products to thousands of clients in Latin America, North America, Europe, Africa, and Asia. As part of its growth strategy, the company made multi-million-dollar investments in research and development facilities, manufacturing plants, and dedicated sales centers across Latin America. Read More
Solution	To overcome these challenges, Duas Rodas designed enterprise-wide best practices to break down operational silos and control business processes from end to end. The company deployed SAP ERP applications on an IBM Power Systems server platform to support this new way of working. The SAP ERP solution included applications for Finance, Controlling, Materials Management, Sales and Distribution, Production Planning, Research and Development, Project System, Quality Management, Plant Maintenance, and Warehouse Management. To ensure high levels of availability for the mission-critical SAP ERP applications, Duas Rodas implemented IBM DB2 for Linux, UNIX, and Windows with high availability disaster recovery (HADR). Read More Log in to view content
Contents

Technology Category

Functional Applications - Enterprise Resource Planning Systems (ERP)

Processors & Edge Intelligence - Embedded & Edge Computers

Processors & Edge Intelligence - System on a Chip

Applicable Industries

Food & Beverage

Applicable Functions

Discrete Manufacturing

Procurement

Use Cases

Manufacturing System Automation

Predictive Maintenance

Services

System Integration

Training

Challenge

Duas Rodas, a Brazil-based food additives manufacturer, aimed to achieve a sales target of USD 450 million by 2015 by expanding into international markets. However, the company's existing manufacturing assets were at their capacity limits, making it impossible to meet the increasing demand. The company's growth strategy involved significant investments in people, machinery, and technology, but a lack of standardized processes made it challenging to align manufacturing throughput with demand. The business units operated independently, and the lack of integration between client orders, inventory levels, and production planning made it difficult to achieve the necessary manufacturing output.

About Customer

Duas Rodas is one of the largest manufacturers of food and beverage additives in Latin America. Founded in 1925 in Jaraguá do Sul, Brazil, the company has grown significantly and now operates in several countries including Brazil, Argentina, Chile, Colombia, Peru, and Mexico. Duas Rodas employs more than 1,400 people and exports its products to thousands of clients in Latin America, North America, Europe, Africa, and Asia. As part of its growth strategy, the company made multi-million-dollar investments in research and development facilities, manufacturing plants, and dedicated sales centers across Latin America.

Solution

To overcome these challenges, Duas Rodas designed enterprise-wide best practices to break down operational silos and control business processes from end to end. The company deployed SAP ERP applications on an IBM Power Systems server platform to support this new way of working. The SAP ERP solution included applications for Finance, Controlling, Materials Management, Sales and Distribution, Production Planning, Research and Development, Project System, Quality Management, Plant Maintenance, and Warehouse Management. To ensure high levels of availability for the mission-critical SAP ERP applications, Duas Rodas implemented IBM DB2 for Linux, UNIX, and Windows with high availability disaster recovery (HADR).

Impact #1	The implementation of SAP ERP applications on an IBM Power Systems server platform enabled Duas Rodas to break down information silos and deliver full visibility of company-wide performance to senior decision-makers.
Impact #2	The new system allowed the company to automatically integrate accurate, real-time data on client orders, inventory levels, and production planning in a single system, reducing the complexity of the manufacturing process and increasing efficiency dramatically.
Impact #3	The company can now complete daily production planning tasks in just 20 minutes, an improvement of 80 percent.

Impact #1

The implementation of SAP ERP applications on an IBM Power Systems server platform enabled Duas Rodas to break down information silos and deliver full visibility of company-wide performance to senior decision-makers.

Impact #2

The new system allowed the company to automatically integrate accurate, real-time data on client orders, inventory levels, and production planning in a single system, reducing the complexity of the manufacturing process and increasing efficiency dramatically.

Impact #3

The company can now complete daily production planning tasks in just 20 minutes, an improvement of 80 percent.

Benefit #1	Accelerated production planning by 80 percent.
Benefit #2	Significantly boosted throughput, helping to satisfy demand in key international markets and facilitating the USD 450 million sales objective by 2015.

Benefit #1

Accelerated production planning by 80 percent.

Benefit #2

Significantly boosted throughput, helping to satisfy demand in key international markets and facilitating the USD 450 million sales objective by 2015.

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Overview

Duas Rodas achieves 80 percent manufacturing productivity gains

Operational Impact

Quantitative Benefit