Case Study
Dawn Food Products
The Right Mix for Implementing a Custom Warehouse Management System
Dawn Food Products, Inc. (Dawn) is a global producer of bakery products and one of the world's largest independently owned bakery manufacturers and distributors. Dawn manufactures and distributes a complete line of high-quality, consistent mixes, bases, icings, glazes, fillings, frozen dough, par-baked and fully-baked products. Dawn needed a warehouse management system (WMS) that would facilitate compliance with the 4 hour window for retrieval of data mandated by the FDA for establishment and maintenance of lot tracking records for human and animal food product ingredients under the U. S. Bioterrorism Act (2002). TranSystems | ESYNC developed a detailed Project RoadMap(SM) for implementation and integration of Dawn's custom WMS to provide complete lot control and visibility across the Dawn supply chain network, as well as provided program and project management and comprehensive training and on-site support for Dawn's 7 x 24 operations.
Project challenges included an aggressive rollout schedule and adaptation of a custom WMS that was initially configured for a dry ingredients processing facility but needed to address the specific needs of ambient, wet, dry and freezer operations at other sites without jeopardizing overall system “look and feel”, integrity or performance.
TranSystems | ESYNC created a comprehensive Project RoadMap that served as the guide for meeting the FDA deadline. Then, in conjunction with the Dawn team, TranSystems | ESYNC adapted and implemented the system for each of the fifteen (15) Dawn sites in six months.
All rollouts were completed by the deadline and the project came in under budget. Facility productivity reached pre-implementation levels within one to two weeks of each site’s go-live. Efficiencies gained included a 67% reduction in the number of bar code scans required for product tracking and manual data entry time savings. TranSystems | ESYNC produced extensive system and procedural documentation that is now used by Dawn systems and operating personnel.
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