Case Study

How Contract Packers Can Cut Costs and Win Back Time

How Contract Packers Can Cut Costs and Win Back Time

This session introduces how leading co-packers are using purpose-built contract packing software to improve traceability, efficiency, and customer satisfaction. Hosted by Josephine Coombe, Chief Commercial Officer, and Jake Golden, Senior Solution Engineer at Nulogy, the webinar features insights from Tom Kennedy, Operations Lead at Prism eLogistics—one of the UK’s top co-packing providers and a long-standing Nulogy customer.

The agenda includes a discussion on real-world digital transformation, followed by a live demonstration of Nulogy’s platform. Attendees also receive a recording and follow-up survey.

Revist our webinar featuring Prism eLogistics and Nulogy’s Shop Floor Solution, and hear how a leading co-packer is modernizing operations, improving traceability, and unlocking new growth.

Hosted by Josephine Coombe (CCO, Nulogy) with insights from Tom Kennedy (Operations Lead, Prism eLogistics) and a live product demo by Jake Golden (Senior Solution Engineer, Nulogy), this session explores:

  • Real-world digital transformation: How Prism replaced manual processes with real-time visibility, labor tracking, and scan-based traceability—reducing recall reporting from 9 hours to 20 minutes.

  • Operational excellence through digitization: Enhanced accuracy, quality checks, audit readiness, and end-to-end traceability that boost customer confidence.

  • Scaling smarter, not harder: Why co-packers are embracing purpose-built software to support growth, improve profitability, and meet rising client expectations.

  • Live demonstration: A walkthrough of Nulogy’s shop floor capabilities—from scheduling and WIP visibility to digital BOMs, mobile picking, inspections, and recall reporting.

About Nulogy

Nulogy is a global software company with offices in Toronto, Belfast, and near Bristol. The platform supports a broad customer base—from small contract packers to major multinational logistics providers such as DHL and GXO. Nulogy is also used by major FMCG brands including Mars, Colgate, P&G, and L’Oréal.

The company partners with industry associations such as the BCMPA and is recognized as the leading provider of purpose-built contract packing software. Unlike generic systems or manual solutions, Nulogy models the unique workflows, production variability, and traceability requirements of co-packing environments. Hundreds of sites around the world rely on Nulogy to manage complex, fast-moving operations.

Prism eLogistics

Prism eLogistics provides co-packing, rework, shrink sleeving, and fulfillment services across a wide range of SKUs. According to Operations Lead Tom Kennedy, increasing client expectations around traceability, data availability, and real-time reporting drove the company to explore digital transformation.

As product complexity has grown—such as the expansion of SKU counts and seasonal promotions—manual workflows began limiting speed and accuracy. Paper-based processes created delays, errors, and trust gaps with brand owners who required instant visibility and accurate reporting.

How Digital Transformation Changed Daily Operations

With Nulogy, Prism shifted from manual, paper-heavy workflows to a fully digital environment:

  • Real-time visibility into work-in-progress, labor, and materials

  • Digital work instructions and repeatable work orders

  • Barcode scanning for pallet-level traceability

  • In-line quality checks and reject tracking

  • Instant visibility into finished goods

  • Accurate labor and performance metrics at shift end

Teams now have immediate access to production data, enabling quicker decisions and smoother operational flow.

Why Prism Chose Nulogy

Prism evaluated internal development and generic software but found neither approach fit the specialized needs of contract packing. Nulogy’s deep industry expertise, scalable platform, and proven track record made it the best option. Prism has now used Nulogy for over a year and a half across multiple production lines.

Business Impact and Results

Complete traceability:
Product recalls that once took nine hours now take roughly 20 minutes. Prism maintains audit readiness at all times.

Real-time control:
Leaders can monitor operations remotely and respond to issues immediately.

Higher profitability:
Accurate data improves labor planning, productivity, and material usage. The improvements have strengthened Prism’s reputation with brand owners, increasing growth opportunities.

Lessons Learned for Co-Packers

  • Begin digital transformation early—before processes become unmanageable.

  • Involve staff at every stage to build engagement and ensure smooth adoption.

  • Treat digitalization as a long-term growth tool.

  • Rely on expert implementation support for successful rollout.

Prism found that even team members who were initially hesitant have become strong advocates after experiencing the benefits first-hand.

Good afternoon, everybody, and welcome to our webinar today.

It’s good to have such a good audience for today’s session, and I’m delighted that you could make the time today.

So I’m joined today by Jake Golden, who’s our senior solution engineer from Newlogy. My name is Josephine Coombe. I’m the chief commercial officer at Newlogy. And we’re really delighted also to be joined by Tom Kennedy, business development manager at Prism eLogistics, who is one of the leading co packers in the UK and also a valued customer of Neulogy. So thank you so much for for joining us today, Tom.

Great. So we’ve got quite a packed agenda today. We’ll be with you for about fifty minutes. We’re going to have an interview with Tom discussing their real world use of Neulogy at Prism. And then Jake is going to take over to do a demonstration of the software for you and there will be some time to pose your questions to the panellists as well.

But do please feel free to also put questions in the chat.

We answer some of them as we go as well.

Today’s session is being recorded, so rest assured that there will be a copy of today’s session sent to all the attendees. So if you have colleagues who were really interested in attending but perhaps couldn’t make it today, not to worry, they will be able to watch the session afterwards.

And also, Sultana, who kindly handled all the logistics of today’s event, will be sending you a little survey afterwards. So please do take a moment if you can spare the time to give us your thoughts on how today went so that we can improve these sessions for the future.

Great. So we’ll move ahead. For for those of you who are new to Newlogy, we’re a software company. We operate around the globe, and we have offices in Toronto, Belfast, and just outside Bristol.

We serve a diverse customer base ranging from small dedicated contract packers up to some of the largest logistics companies in the world like DHL and GXO and so on, who provide co packing as a value added service. We also serve a wide range of manufacturing companies, again, from small to large, including some of the biggest FMCG firms in the world, such as Mars, Colgate, P and G and L’Oreal.

We are very happy to work with a number of the industry associations, and in particular I would like to call out BCMPA, who kindly partnered with us on today’s webinar. So big thanks to them who’ve been a very valued partner in in the UK with us.

So so who is Newlogy for the purposes of today’s conversation? Well, we’re really focused in on one aspect of our platform, which is our contract packing software. And I think it’s fair to say that we are the leader in this space. In fact, arguably, really the only software available globally that has been purpose built specifically for co packing workflow.

And not only that, but we are trusted, proven, deployed successfully in hundreds of sites around the world from large co packers to small. And so we’ve seen a very diverse range of co packing environments.

That experience is really embedded in our culture and we have a product development team as well as a services and support team who have really, for a software company, unparalleled expertise in co packing. So that when you work with us, you know you are working with a software company who actually understands Copac as opposed to really only just understanding software.

And finally, we are able to support you wherever you are. We have customers all around the world.

And on the next slide, you’ll see some of the successful deployments that we’ve had here in the UK and mainland Europe, from companies like Marsden Packaging and Prism, all the way up to fifty site organizations like Nagel Group and serving DHL and GXO and others all around the world.

So that’s a little bit about Newlogy, but let’s zero in now on Prism, one of our customers. And, welcome, Tom. Perhaps, Tom, you’d like to introduce yourself and Prism just to get started?

Yeah. Sure. Hi, everybody. Obviously, Josephine, for this opportunity to come on board with Nulogy today.

I am the operations lead at Prism Logistics. We range from co pack, rework, shrink sleeve in fulfillment, kind of a one stop shop for all your rework needs.

Yes. That’s us as a whole. I don’t want to go too much into the the talk.

That’s great. That’s great. Well, maybe we’ll start with a bit of a macro sort of view in terms of the kinds of challenges that co packers generally, not necessarily just Prism, but co packers generally are facing in the market today. Can you give us some sense of that?

Yeah. Sure. Look. I think the rise in expectation from clients now is is growing. It’s it’s changing.

They they all want instant traceability. They want instant data. They want instant reports.

The old school method of the manual process, the paperwork, it caused delays. It caused errors. It there was a loss of loss of trust, not through what we’re doing, through the amount of time it takes to get to that position.

Nowadays, you look at the you look at the market, you look on shelves, and there’s no longer one single Coke brand. There’s twenty eight different SKUs of Coke.

That’s a challenge for every every co packer, every re worker. And I guess taking it away from the work side of things, seasonal work, promotional work all comes with labor. Right? You need to to have the labor to support your business and to be able to understand and identify that is is a massive challenge for co packers.

Right. It’s a very labor intensive business. And and and sometimes, actually, it’s interesting because people assume perhaps that technology can’t be applied because it’s so based on handwork in a lot of cases. But but, actually, you’ve seen how technology can be applied.

So so tell us a little bit about that.

So this is why I I’m smiling, Josephine, because Nulaji has answered so much for us.

So now we have real time visibility of our WIP. So you work in production. We know what inventory we have sat in the warehouse. What status?

Is it in pick? Is it being picked? Is it actually in the job? We’ve got real time labor as in how much we put into that job.

So that’s kind of one aspect of the the work.

But before the work gets to the line, digital bill of materials, work instructions, we get a lot of repeat business at Prism. And sometimes, the little things change here and there, and it’s not picked up by the old paper style working. So now we’ve got digital on hand. We can repeat works orders. It’s all scan based.

So traceability working back to the traceability side of things, every pallet is scanned from when it comes into the building to when it leaves into the production.

That’s that’s this saved endless hours for us.

And then the givens kind of the live reporting that we can now get aids better decisions to be made.

And like I said before, just going back to that customer satisfaction piece where they’re confident now because we’re getting them results within thirty minutes, an hour, as opposed to nine hours. It just unlocks that confidence with Prism and for the client using us too.

Right. Right. And and, you know, really as a as a co packer serving a brand, you’re you’re responsible in some ways for their reputation. So being able to deliver that assurance through recall readiness and so on gives them confidence in in you.

Yes.

So so you were you were looking for a new system for some time.

Tell tell us a little bit about what led you to start looking for a system and and then the actual process of finding one.

Because it wasn’t it wasn’t that short, was it? You you took a little bit of time with that with that evaluation.

Yes. Yes. It was again, I’m smiling because it was a lot of my life that was taken up with with this.

Yeah. Look. We we knew we were growing. We knew we were grow growing rapidly.

We knew that the market and what the clients wanted, we wouldn’t have been able to do using the methods that we used.

Now we we looked at doing this ourselves.

We looked at making our own system. We use an a different system for a different part of our business. We tried to adapt that, and it didn’t work.

So yeah. Look. Going back to your question, we we knew we had to get something that worked in place to be able to deliver to our customers what they wanted.

So that so that’s interesting. You, you know, you you considered the route to building your own. You considered trying to make other systems that perhaps are not actually built for Copac work for Copac.

Neither of those routes sort of turned out terribly well.

I think, you know, when people are looking for a a one size fits all, it’s usually because they’re hoping to get some economies rather than having to buy, you know, separate systems for for different aspects of their business. You know, is that a sort of false economy, that approach?

It doesn’t. It it it doesn’t exist. I can I can I can tell you if and if you can, please let me know? But I can tell you now, we’ve I’ve scouted.

I’ve scoured the Internet, and it doesn’t exist. The Right. The co packing is such a niche market and kind of work stream that it’s forever changing. It’s you need you need a software that, as you said at the very beginning, that understands copack and the industry.

And that’s that is ultimately, that is why we chose Nulogy.

Great. Good. Well, we’re very glad you did. And so so that sort of best of breed approach, you’ve been living it for a while now because you’ve had Neulogy in place for for what, at least a year and a half or so now.

Tell me about a day in the life of Tom Kennedy using Neulogy, because you you personally use it pretty much every day. Is that right?

Yes. I I mean, do you want me to talk from a business perspective or a personal perspective or maybe a bit of a hybrid perspective?

A bit of both would be would be interesting.

Okay. So I’ll I’ll go through it very briefly. So back a year and a half, two years ago, my role comes consisted of the planning, when we’re going to get stock in, do we have enough stock, How many SKUs does that stock go into and how many we can make? Then I actually made the plan, made the labor, put it into a work a bill of materials to make a works order, to put it down to the line, to brief it to the team.

And I it’s to do that over twenty, thirty different clients over a rolling period, it was painful. So now a day in the life, I don’t do any of that anymore. So the work is preplanned using the scheduler.

The supervisors look at the works order orders digitally. They get released to the teams. The team leaders open the works order. They can see what they’re producing.

The system automatically looks at the materials.

The materials are scanned into the line. The operators record our outputs and our rejects, which I just want to put in there we didn’t do before. Quality checks are done on the line the second they happen every thirty minutes, forty minutes, every however you want to put it.

The finished goods then are instantly visible for us to see. And then at the end of a shift, obviously, the the costs, the productivity data are there instantly.

So that’s from a being self sufficient, that is our business now. From my point of view, I can be at home. I can be in the car. I can be at a Starbucks, and I can log in and see how we’re operating on jobs, on works orders from anywhere in the world.

Right. That that’s so interesting to hear you tell this story, Tom, because certainly one one thing I see and hear a lot when I’m talking to co packers is that there’s often, you know, one chap who knows everything, and it’s all locked in his brain. And with Newlogy, you can kind of liberate that knowledge, democratize it, and make it available in the system so that the whole company can can benefit from that and you’re not dependent on or so dependent on those key personnel who, you know, who have intelligence kind of locked in their own in their own mind. So, you know, I’m I’m I’m very glad to hear that it’s kind of allowed you to be a bit more flexible as well in in your role.

Yes. Definitely. The growth, yeah, the growth for the team and the business is is tenfold. It’s it really is.

Fantastic. Good to good to hear. You mentioned earlier, you you touched on reporting and traceability. And and certainly, one of the things that we hear from our major brand customers is that they’re often seeking out Newlogy powered co packers precisely because they understand that being digitalized allows you to be recall ready, deliver reporting more accurately and faster.

So so that’s a that’s a growing need, you’ve found that’s been accelerated now that you’ve you’ve got Newlogy. Correct?

Yes. Yes. One hundred percent. I’ve got I love I’ve got a story which you’ve heard many of times. Back a year ago, I had to do a product recall, and it took me seven different panes of glass, three different pens, and nine hours to do a full recall report.

I’ve done one last week, the week before. It took me twenty minutes, and about five minutes of that was making a cup of tea.

It’s it’s I I do make a joke about it, but that’s the level of detail that Newligy has put in to our business through processes, through scanning pallets in every stage.

Okay. It can be it can slow down your production, but everything is correct. Everything is right. And I have a hundred percent faith now on our stock holdings. If you asked me a year and a half, two years ago, I would have probably said about twenty percent.

So big big lift there. Good good stuff.

You know, there’s probably people in the audience, though, today who have considered a digital transformation, and one of their big concerns is how will staff adapt. You know, there are lots of co packers out there who’ve been operating for ten, twenty years or more, and they’ve got staff who’ve been there a very long time, and there is concern about how to manage that change to a new way of working.

What was that like? What was the implementation like? How hard was it to manage that change?

Yeah. The another again, another funny story. You’ve you’ve nailed it nailed it there.

Our team was also like that. Our team has been together for five, six, seven years. They’ve all got experience in the industry.

Again, I keep going back to the old way of doing things with paper and spreadsheets.

Their mindset was, why are we changing?

It works.

Everything works now, but they didn’t see behind the scenes of the product recalls, the conversation with clients. So at first, they were very standoffish.

We we got them involved early, and I think that’s a very good point to get them involved in understanding the change. But the real the real difference was Nulogy’s implementation of the system. So as a business, we we correct me if I’m wrong, Joe’s thing. Was it three or four weeks we had setting up the system behind the scenes?

And then we had two of your staff members come on-site Right. That were very knowledgeable, very helpful.

Again, the team, very standoffish. The two gentlemen were brilliant. They’ve heard it before. They’ve seen it before.

They held their hands. They were down on the shop floor. They had their hi vis on, their hair nets, and they were going through job by job with tip sheets, cheat sheets to help them move through of the productions.

Clear communication.

And I think to have an internal champion is is your best bet.

But going back to your question, they were very standoffish. The team came on board, held their hands through it to a point now where I was the champion, and now they know more than me.

Right. But but very interesting. I mean, the you know, I always think it’s curious with people are sort of naturally resistant to change, but they’re also incredibly adaptable to change. So often you get this kind of initial resistance, but it can very quickly with with good professional services support and, as you say, an internal champion, quickly turns into people actually really appreciating the new way of working.

So Yeah.

It’s scary, right, when when you change when you’re changing something you do when you don’t know the benefits of it.

Right.

But I think the point was they saw the benefit very quickly. And although it was a couple of extra steps, in the long run, it saved so much time in their day.

Good. Good to good to hear. So so on the topic of benefits, if if you had to sort of summarize the three biggest benefits to Prism of undertaking this digital transformation, how would you how would you describe those?

First one to roll off my tongue very easily, traceability, because it’s a soft spot to me.

At any time, the system is audit ready audit ready to be traceable through multiple SKUs. That’s number one.

Number two, I would say real time operational control.

At any at any point, you can log in, and you can see exactly what’s being done on the shop floor, what’s being created, what’s been your revenue. Is it efficient? Is it effective?

And then that kinda leads into number three would be we’ve been able to improve our profitability through the recordings and the data that Knowledge is can provide us. Accurate data as well. Sorry.

Alright. Good good stuff.

And and so, you know, for the folks in in in the audience today who are here to hopefully benefit from from your experience, is there two two part question really. One, is there a right time to do this? And and secondly, what other considerations should they have in mind as they, you know, as they potentially embark on on a similar journey?

Yeah. Okay. So I think from from experience, do it before the before you see the cracks. Don’t wait don’t wait for it to don’t wait for something to fail before you start to think embarking on this journey. Do it now. And if you can’t see your real time data with your labor versus your production, your revenue, again, now is the time.

Yeah. I think that’s that’s that’s probably my key thing. Start start early. Keep it simple. Involve your team and build the momentum rather than put Band Aids on it.

Right. Very very interesting remarks because, you know, we we have certainly, we have had a few customers who’ve come to us perhaps when things were starting to sort of strain at the seams as it were.

But a lot of customers come to us precisely when they’re doing well because they recognize what you’re saying. They they recognize that when you’re growing, when you therefore need to scale up your operation, it’s best to get ahead of that rather than to wait until until things break. I mean, can help either way, but but agree with you that it it makes a lot of sense to to try to be proactive rather than than reactive and sort of put bandages on it. But, yeah, good good points on there.

So we’re we’re gonna actually see the software live shortly. Is there anything else, Tom, that you think is important to mention before we sort of close off this this interview portion of the the webinar?

Not not that comes to that comes to mind. I think I’ve covered a lot of it in what I’ve said today.

For sure.

For sure.

I may be coming to I’m very passionate about Nullaji. Personally, for my growth and my career, the business’ growth, but on top of all of that, actually, the team’s growth, the people that work with us

We’ve seen we’ve been able to put ourselves in a biz position where bigger clients are actually now coming to us through word-of-mouth because they know what we’ve done, and they know what we’re now capable of.

Right.

Because we’ve got this data. We’ve we’ve got the reports. We’ve got the traceability.

It is in place. There’s no there’s no spreadsheets causing risks. Somebody overdoing data.

It’s controlled. It’s a it’s a controlled environment now from start to finish even with your planning and your and your revenue.

We’ve got a we’ve got a fix on it. And and I would I I really just want to emphasize that use it as a growth mechanism.

Don’t use it as a fix when it’s broken. Do it now.

Because that that’s that’s actually really interesting that you’ve you’ve so much appreciated the fact that digitalizing isn’t just about improving internal operational efficiency, it’s it’s also a growth driver.

It is a strategic competitive advantage in the marketplace that you can leverage to earn the trust and the business of particularly those larger clients who who care about things like traceability and and recall readiness. So I’m glad that that’s delivering benefits on the growth side as well for you. So wonderful. I really appreciate your comments today, Tom. And Tom will be on the rest of the webinar and we will have a section Q and A, but also feel free to put your questions in the chat. I’m going to hand over the floor now to Jake, who’s going to show you the actual goods. So let’s turn things over to Jake to show us the software demonstration now.

Jake?

Thank you, Josephine, and thank you, Tom. I’m gonna go ahead and share my screen.

And, Joe, if you just wanna give me a thumbs up or let me know if the screen is showing properly.

All good. Excellent.

Alright. Well, hello, everyone. Thank you so much for joining today’s webinar. As Joe said earlier, my name is Jake Golden. I’m a senior solution engineer with Nulligy.

Today, I’m gonna be giving you a demonstration of the Newellogy shop floor solution. And I think Tom did an amazing job of describing his experience with the solution, how it’s added value to his and his team’s day to day. And I think Tom said it best when he said contract packaging is such a unique industry. And so when organizations are looking for software solutions, if you’re a contract packager, you really need a solution that knows Copac. And so my hope is today after the demonstration, I’ll have illustrated how our shop floor solution was tailor made for the contract packaging industry and adds values to our customers’ day to day lives.

So with that, we’re gonna start by looking at the home screen of the Neulogy shop floor solution. I like starting here for a couple of different reasons.

One of the reasons being as our customers adopt the solution, one of the things that is very important to us and some very intentional design choices that we’ve made with our solution is that the solution is both easy to use and easy to adopt for frontline workers who are line leads or operators on the production floor or in the warehouse as well as the users who are on the planning side in the back office doing the heavy lifting to make sure that production runs smoothly.

You’ll notice with the home screen as well as other areas of the solution, we’ve made our system very visual. It’s very easy to understand where I am.

You’ll notice where I am in the workflow, and I think the home screen does another good job of illustrating the breadth of functionality in the ShopFloor solution. And while we won’t see everything in detail today, I wanted to start here to show you all of the different capabilities the ShotFloor solution has to offer.

One of the first things that I think is really important to dig into is something that Tom had mentioned earlier, which are some of the master data elements that would be stored in Nulogy that are gonna be foundational to some of the functionality we’re gonna see as we move through the demonstration.

Now Newlogy will, of course, be the system of record to manage customer orders or as we refer to them in the system as work orders.

And in those work orders, we can store critical master data such as the item master as well as that item’s bill of material.

So Tom said that for his team, having that digital bill of material not only helps from a master data perspective, but as we’ll see in the rest of the demonstration, it’s also going to drive different processes, whether it be in inventory when we’re managing different workflows in the warehouse, all the way through to production to make sure that the right products are being used, and we’re controlling for different elements as it pertains to track and trace. For example, this would be where we establish if an item is lot or expiry controlled.

We also have the ability to support different versions of the bill of material. So if there are changes to the ingredients or the components throughout the year, maybe there’s a seasonal variant, this allows us to easily manage that change without having skew proliferation in the system.

As I go back into the work orders, I’m gonna scroll quickly down to the jobs portion of this work order.

Now you can think of a work order and a job as a bit of a hierarchy. At the top, you would have your customer order, which is your work order. And below that, you may have one or multiple jobs scheduled to actually execute against that production.

And you can think of a job as a shift of production taking place on a specific production line.

Now I’m gonna bring us into the job page, and this is gonna do a really good job of illustrating both what it’s like for line leads or someone who’s actually at the line using Newlogy on the floor. And this will also give me some opportunities to talk about some of the elements that Tom had mentioned in his interview, both how we capture things like labor utilization during production, how we’re tracking the critical track and trace information throughout the entire process, both from receiving product into the facility, picking it for production, all the way through transforming that product into its final finished good. And later, we’ll see an example of how the reporting wraps all of that up so that we can do recalls in just a couple of clicks.

Now on the job page, something that I had mentioned earlier is, again, we very much designed our system to be easy to use and only present the information that’s relevant to the operators so that they can do their jobs quickly and effectively.

You’ll notice as I go through the job page, we’ll be scrolling from top to bottom. So you can imagine as a line lead or someone working on a production line, as I go through my process, it’s a very simple process of scrolling from top to bottom as I enter new information.

At the top, you can see where we have our play, pause, and stop button. This allows users to very easily both initiate production by pressing play, but then also if there are breaks or any pauses to production throughout the process, very easy for them to click the pause button.

And here, we can add customized reason codes to actually identify why we’re pausing production. So it can be something simple, like the team is taking a break. It could be something more critical, like a machine goes down or there’s a quality hold.

In any case, once that reason is specified, users can also add notes. And if I were to initiate that downtime event, it would log in in the system.

And this is important for a couple of different reasons. This helps our customers not only understand why lines or production lines are being paused or going down. It’s showing the reasons for those downtimes, and it’s also going to incorporate that data into the efficiency metrics that are tracked throughout production.

Now something that Tom said in his conversation was how the solution gives the information to the frontline workers that is going to help them with their data take desks. So for example, the information that you see here isn’t information that a user would have to key in every time they enter a job or start working. It’s largely pulling this data from the work order or the item master. So if a user needed visibility into the build or the bill of material, If there were work instructions that would be helpful for production, those can be presented to the user directly on their job screen.

As I scroll down further into the job page, you can see where we can actually track the labor that’s being utilized for this particular production activity.

Now in some cases, customers will actually arm their employees with barcoded badges, in which case they can scan their badge into the system. I’ll just type my user here as an example.

When I enter that time record, you’ll see here that it’s going to show anyone who scanned in or has been clocked out of that particular job.

What’s really nice about this method is that if, for example, labor switches between lines to help out, once that person goes and scans their badge into another job, the system will automatically clock them out of the job they’re working in previously. So, again, we’re being as accurate as possible when it comes to labor tracking.

Additionally, we understand in some environments, it’s easier to add labor manually and have it be more generic across the different people working on the line. So we also accommodate for that with the manual entry. So, for example, if I wanted to add five people to this line, it’s very simple for me to do that.

Once I’ve added those labors, they’ll see them here in the time records.

Now in addition to the number of workers and the people who have been involved in this particular production activity, we’re also capturing a cost rate associated with each unique badge type. So, again, we’re being as accurate as possible with not only the utilization of labor, but the cost for this particular job.

Now something that is critical not only in production but throughout the entire facility is quality. And one of the elements that you’re seeing on the screen right now is the quality sheets and inspection panel. This is going to show me any quality inspections that were performed for the specific job. So Tom did a great job of explaining how in his environment, every thirty minutes or hour or specific time cadence, there’s an inspection that’s taking place in line.

Those inspections are being done digitally using Newellogy’s digital quality inspections, and they’re populating directly on the job page like we’re seeing here. This way, for any of our customers that have to produce electronic batch records or report on any inspections that took place in line, they’re easily reportable and visible not only to the production team as production takes place, but also to management who may want to report on that data.

Now this next section that you see here is our materials panel. This allows me to capture and scan inventory that’s coming into WIP for this particular job, WIP being work in process.

Now I’m gonna use this opportunity to showcase some of the warehouse management capabilities of the system by performing a production pick list. So if we kind of imagine where we are in the facility right now, looking at the job page, I’ve been acting as, say, a line lead working at a production line. At that workstation next to the production line, I would have my laptop or computer paired up with a label printer and Bluetooth scanner. And I’m now switching hats, and I’m going to take the role of, say, a forklift operator or a material handler in the warehouse.

Now what I’m showing here is Newellogy’s mobile interface largely used for our warehouse management and inventory management workflows. We won’t have time to look through all of those today, but you’ll notice that it’s a very user friendly interface. We would typically see this on a tablet or a mobile device paired up with a Bluetooth scanner so that users are both guided by a system, but then also can easily interact with inventory and production as they move throughout the facility.

For today’s demonstration, I’m gonna use this to perform a production pick list. This is going to be where we grab inventory from the warehouse and bring it to a specific production line where that inventory has been allocated for a specific work order.

Now to do this, I’ll select the pick list icon from my home screen, and you’ll see here that there are a number of pick lists that have been assigned to me. I’ll select the pick list here that’s going to our line one staging location.

When I do that, you’ll notice the system is presenting the items that need to be picked. For demo purposes, I just have one item that we need to pick today. But if there were multiple items, I’d see them in my drop down here.

Additionally, there are controls in place, which we’ll see in just a moment, to ensure that not only the right item is being picked, but we can also be specific to ensure that the right lots and expiries are being picked throughout the process as well.

I can see the available locations where this inventory is available. So, again, from a guidance perspective, makes it very easy for material handlers and forklift operators to know exactly where they need to go and what they need to pick. As Tom said, with use of the system, your inventory levels are kept accurate and up to date, not only when you receive inventory into the facility, but as it moves around, as it goes to the line, as it’s consumed, the system is updating that information in real time.

So here, I’m gonna go ahead and make my way over to one of these locations, I’m gonna scan one of these pallets out of inventory.

Now like I said earlier, there are verifications in place so that if I do make a mistake and scan, say, the wrong item out of inventory, the system’s going to tell me that.

So here, I’m actually gonna pick up the wrong pallet on purpose. So let’s say I was one rack location to the left. Here, you’ll see that this is showing me that the item is not on my pick list. Thus, it won’t let me pick up the item.

Again, ensuring that the right products are being to the being brought to the line.

Now for time’s sake, I’ll go ahead and just pick the correct item here, and we’ll bring it over to our production line.

So when we pick the right inventory, it’s giving me a success message, and it’s also directing me to where this inventory needs to go. So I’ll make my way over to that line staging location. And from here, I can scan my location barcode, and from here, drop off the pallet.

So great. That pallet is now line side. If we kind of switch gears again, I’m now that line lead, and I’m gonna go ahead and scan that pallet into WIP at the production line.

Now just like we saw earlier, if someone were to try to scan the wrong pallet into inventory at the line, they would receive an error. For time’s sake, I’m gonna go ahead and scan the correct pallet into inventory. You’ll see that this was successfully moved.

And part of what makes the system so powerful from a track and trace perspective is that as these movements take place, we’re capturing all of the relevant information along the way. So here, for example, if I open up my consumption ordering for this particular job, it’s gonna show me pallet level, lot and expiry level details for every component, every material that was brought to the line, and how it’s being consumed.

Now at this point, we have our labor. We have our materials. We’ve began production. As products start to roll off at the end of the line, I can start to report that production.

And here, I’ll just report this as a full pallet, which is a pretty common unit of measure that our customers would be reporting end of line. And when I add that pallet of production, you’ll see that the system generates a pallet tag. I can then print this finished good pallet tag, apply it to the finished good pallet that’s been produced, and it’ll be ready to go into inventory. The output of these pallet tags can also be customized to match any specific requirements you may have, whether it be formatting or your customer specifications.

You’ll see as I report that production, that production is being logged in real time for the line lead. So they have visibility into not only how close they are to completing the order, but the overall performance of their team on the line.

And, of course, that’s great visibility for the line leads, but we also wanted to provide this visibility for management or supervisors who might be looking at this production performance data across an entire site.

Our production dashboard gives you that visibility into different lines that are running different jobs, how close those jobs are to being completed, as well as the performance hour by hour.

Now this, of course, is just a high level overview of the production and the consumption capabilities of Newellji shop floor, but I’d be remiss if I didn’t mention some of the planning capabilities that come with the system as well, such as our drag and drop visual production scheduler that Tom mentioned. This makes it so that our customers can easily sequence orders across their different production lines. The system is taking into account production standards so that when I schedule one of these work orders onto my schedule, it’s automatically sizing that block to accommodate for the right amount of time on my schedule. This enables our customers to make sure that they’re not only maximizing the labor that’s being used in production, but they’re maximizing the capacity of their equipment and different production lines. And it’s this flexible visual schedule that helps our customers ensure that they’re getting orders out the door on time for their customers.

Additionally, as I mentioned earlier, Nulogy has a full suite of digital quality inspection capabilities, whether it be the quality dashboard, which shows me hour by hour any inspections that have passed or failed or the inspections themselves that allow me to have a digitized copy of any what might be traditionally paper based inspections that I’m performing at the site. This allows me to not only ensure the right people are performing those inspections, but it gives me the flexibility to add different inspection criteria. I can take pictures during that inspection, and I can also get electronic signatures along the way.

And so to conclude our demonstration, I wanted to showcase something that Tom had talked about, which is some of our reporting capability. And, specifically, I wanted to showcase an example of our recall report.

For many of our customers and for the customers that they serve, track and trace information is such a critical element of the production process. And so here, what I’m gonna do is specify a particular component within a particular lot.

When I do this, the system is going to first identify any impacted finished good lots that utilize this during production, and I have full traceability on where that material was consumed, when we received it in our facility, where it is in the facility. So if I wanted to quarantine inventory before it’s used in production, I can do that as well.

And the report also gives me forward visibility to this information as well. So if any of these finished goods were produced in the facility, I can see the work order and job they were produced on as well as where they are in storage and if I’ve shipped any to any customers. And this is giving me pallet level details, lot and expiry specific details on forwards and backwards traceability, everything that comes in all the way through the production process to what goes out in my facility.

Related Content

Drive for Zero Defects Webinar

Webcast: Drive for Zero Defects

Watch as we uncover strategies to harness the power of data-driven decision-making, streamline supplier quality processes through automation and empower your teams to eliminate defects before they impact the bottom line proactively. 

Ready to learn more?

See how Nulogy can reduce costs and drive profitability for your business.