Denver, Pa.-based High Concrete Structures, Inc., a leading producer of structural and architectural precast concrete for parking structures and commercial buildings, recently implemented new planning software that company executives expect will dramatically enhance production, inventory tracking and order dispatch. As the first parking structure product specialist to use Elematic EliPlan by Finland-based PCE, High Concrete has already seen significant improvements at the factory, according to master scheduler Bob Grasser.

EliPlan software is a production planning program for centralized management of overall operations and cost follow-up for precast production. The software was developed in cooperation with concrete products producer Parma Betonila Oy, which has used the software at its 14 Finnish operations since 1998.

“One of the key advantages we've found is the ability to keep all the information in the same place,” reports High Concrete Senior V.P. of Technology Mark Aho. “Managers in various departments then share identical information so they obtain a consistent picture of how all facets of production are working, job-to-job.”

Program developers note that EliPlan integrates system tools for quotations, order handling, backlog balancing, production scheduling, and material and storage management. The main function in the control of production is the scheduling of molds and casting beds. This includes planning daily casting programs for loading the casting pallets or molds. The casting programs can be formed freely from any group of products in the order stack.

Additionally, the program contains various interfacing facilities to implement financial applications, for example, CAD systems or PCE's automated equipment. When creating a production planning system, such versatility offers the possibility of covering all operations at a company's different production units.

“We began our pilot assessments of the software in March of 2002,” explains Grasser. “By late last year, we were putting its many functions to use across all parts of our operations; it's now being phased-in fully. Though we're pleased with early implementation of the software, there are still a few bugs to work out. The inventory bar-code system is one area where we expect to have this resolved.”

“Prior to the new software,” adds Aho, “our multiple departments — including scheduling, engineering, and shipping — had to use four different systems: project software, spreadsheet, database and job costing. EliPlan now offers all of this, with information readily accessible by all departments.”

“When we use EliPlan for scheduling, we have the capability to sort the product by size and strand patterns to make sure the pieces are scheduled in the most efficient manner for the plant to cast, with all information stored and accessed online,” Grasser observes.

“With 120 acres of storage, we've also found it very useful for inventory tracking,” he continues. “The advantage of inventory bar-coding, when it's entirely up and running, will be that customers or inspectors can easily locate and examine their product. When they arrive, the system will provide a printed report that offers an exact location of the pieces in the yard. Location of product in this way will also improve our shipping operations.”

According to Grasser, reporting is another benefit of the system. “Since EliPlan is a centralized database with a lot of information available, our users will be able to select and run reports from the program,” he notes. “The software also allows me to look at future production loads to see if the schedule is overloaded in one production area or underloaded in another. Using long-term capacity planning can help to level the load within the facility.”

High Concrete executives are enthusiastic as well about the software's ability to enhance production of their Mega-Span building system, an advanced solution for construction of total precast office buildings using 15-ft.-wide “Mega Tee” double tee sections. “Our customers — owners, architects and contractors — appreciate the unique scheduling and performance benefits of precast concrete,” says Aho. “With our Mega-Span operations now streamlined with implementation of the software, we offer the best precast solution for office buildings.”
— PCE Elematic, 262/798-9777, www.elematic.com