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ERP in the service of quality - how technology supports construction safety

Case Study

Client

The client is a manufacturer of welding wires used in high-safety structures such as bridges, other engineering constructions, and the automotive industry. In this sector, product quality and traceability are crucial – every batch must meet strict technical standards, and production processes require full tracking of raw material parameters and all manufacturing stages.

The products are distributed both in Poland and internationally- including the United States, where specific customs and quality regulations apply.

Challenges - high-responsibility manufacturing

  • Production and quality processes based on paper documentation — no real-time data access and difficulties in analysis.
  • Lack of precise real-time tracking of raw material and product batches.
  • Need to ensure compliance with legal and industry requirements: mixing raw material batches is allowed only in strictly defined cases; each finished product batch must be linked to a specific steel rod heat number from the mill; it must also be possible to prove during claims or complaint processes that the product met all standards and that any defect originated from the raw material supplier.
  • Lack of tools for accurate calculation of production costs (materials, raw materials, labor costs).
  • Need for detailed data access management: dividing data visibility across multiple branches in Poland and restricting access to sensitive information (e.g., purchase costs, margins, or individual sales representatives’ turnover) based on user roles.
  • Lack of integration between internal systems, production machines, and external partners.
  • Limited production planning and cost accounting within the ERP system.

Solution – ERP as the foundation for quality and cost control

Atteli

ERP implementation

An integrated ERP system based on Microsoft Dynamics 365 Business Central, covering sales, finance, production, logistics, and quality control.
Atteli

Quality control and production tracking

  1. Advanced batch tracking with each batch linked to a specific heat number.
  2. Automatic blocking of raw materials that do not meet quality standards.
  3. Complete history of machines, shifts, operators, and downtimes at the level of each individual spool.
  4. Integration of quality test results with production batches.
Atteli

Access management and security

  1. Advanced permissions system (data filtering by branch, role, and scope).
  2. Restricted access to selected customers and transactions.
Atteli

Flexibility and growth

  1. Processes prepared for new production lines (e.g., flux-cored wires).
  2. Functionality for tracking returnable packaging (drums, spools) and enforcing their return.
Atteli

Digitization and automation of processes

  1. Real-time registration of all operations in the system.
  2. Use of mobile applications and data collectors for warehouse and quality management (eliminating paper documentation).
Atteli

Analysis and reporting

  1. Accurate analysis of production costs (raw materials, materials, labor costs per batch).
  2. Extended financial and operational reporting (balance sheet, P&L, cost accounting).
  3. Reports on goods received without invoices (reconciliation of accounting entries with warehouse receipts).
Atteli

Integrations and partner collaboration

  1. Integration with B2B systems – electronic document exchange replacing paper-based processes.
  2. The project was co-financed at 80% through EU innovation funds.

Results – tangible improvements in production and management

  • Full traceability of raw materials and finished products at every stage of production.
  • Significantly shorter response times to quality issues and the ability to precisely identify the source of any defect.
  • Reduced errors and downtime through real-time process monitoring and the elimination of paper-based documentation.
  • Improved production planning based on up-to-date data on available raw materials, production capacities, and costs.
  • Faster and more accurate financial reporting, including real-time generation of statements.
  • Enhanced claims handling – complete documentation of process and quality compliance available directly in the system.
  • Process optimization across branches – a shared database for 12 locations, with data visibility limited to the necessary scope.

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