Introduction

When it comes to thinking out-of the bo,x innovation has a home at Wisconsin Plastics, Inc.
(WPI). From concept and design to distribution, WPI stands apart from its competition by
delivering quality services with reliable precision. With five locations throughout the Green Bay,
Wisconsin area, WPI provides prototyping, injection molding, metal stamping, powder-coat
painting, assembly, heavy steel fabrication, warehousing and distribution. WPIs full-service
approach has allowed the company to grow to four divisions with more than 200 employees and
over $25 million in sales annually.

Analysis
Wisconsin Plastics, Inc. (WPI) is a full service manufacturer in the Green Bay, Wisconsin area
with four divisions and 230 employees. Pleased with the increased success it has experienced
at its company since the adoption of IQMS manufacturing ERP software, EnterpriseIQ, WPI has
embraced the philosophy of utilizing IQMS for as many of its day to day operations as possible.
WPI determined that introducing new modules at moderate intervals, rather than as a lump sum
of new functionality all at once, works best for its business model and has been improving its
operations at a steady rate.
In an effort to decrease maintenance costs from its legacy payroll system and have more
individuals taking advantage of the EnterpriseIQ software, WPI recently selected to implement
the payroll and time and attendance modules as its next improvement project. Because the
single-database EnterpriseIQ system is so integrated, WPI found the transition to be seamless
across its four facilities, a large time saver and very cost effective. In only three short months,
WPI completely paid for the additional software modules for a rapid return on investment.

Problem
Managing such a fast-paced, diverse manufacturing environment requires strategic control and
visibility across WPIs entire supply chain. However, in the past, WPIs enterprise system failed
to meet demand of the companys four divisions: Modern Plastics which handles injection
molding and final assembly; Modern Stamping and Painting for thin gauge metal stamping and
custom fabrication; Modern Design and Development which brings raw ideas through concept to
prototype; and Valley Plating and Fabrication for heavy metal products. All four divisions had
similar accounting procedures, but varied in operations, inventory and supply needs.
Slow and cumbersome, WPIs ERP system lacked the functionality the company required to win
certification and grow its business to serve a broader range of customers. WPI sought a
comprehensive solution that could manage future growth as well as meet its day-today needs,
including single-system tracking to inform all departments of key activities and superior quality
control to maintain rigorous standards.

Immediate Results from a Single-Source Solution

WPI found IQMS, makers of the EnterpriseIQ system, to be the ideal fit. IQMS offers a
comprehensive, single-source ERP software solution that delivers extensive management

functionality previously available to WPI only through multiple vendor solutions. EnterpriseIQ
uses a single database solution powered by Oracle for improved implementation, ease-of-use
and efficient administration for manufacturing companies. WPI also liked that EnterpriseIQ is
designed for those who use it mostemployees. The systems familiar Windows environment
and intuitive graphical interfaces are so simple to learn that training costs are typically a fraction
of those accrued with other systems.
IQMS provided WPI with an integrated ERP package that supported the companys design and
development, production, accounting and customer service needs. After a brief training and
hand-in-hand work with an IQMS implementation team, WPI saw immediate results.
We wanted to move all divisions to one computer system, said Marty Christensen, Director of
Information Services at WPI. "EnterpriseIQ did that with an easy-to-use interface and
interdependent activities that make tracking a one-click move. Weve seen vast improvements in
several departments.

Better Management Through Enhanced Communication

EnterpriseIQ has also helped WPI better manage its quality standards. Once the system was
implemented, two WPI divisions, Modern Plastics and Modern Stamping and Painting, were
able to receive ISO certification. With EnterpriseIQ in place, WPI was able to take a systematic
approach to meeting stringent ISO standards. The Quality Management System embedded in
EnterpriseIQ increases WPIs visibility and improves the companys reaction time by pushing
data to those who need it, all while using secure electronic signatures and approvals.
EnterpriseIQ also automatically evaluates WPIs workflow status and sends email notifications
to both internal and external team members as needed to maintain the highest quality
standards.
EnterpriseIQ was invaluable in our ISO registration, said John Senter, Quality Manager at
WPI. The manner in which EnterpriseIQ enabled us to inform each effected area of changes or
notices, and document confirmation was integral to the audit. With EnterpriseIQ we were able to
showcase all of the tools needed to supplement an excellent quality system such as corrective
actions, audit findings, statistical process control, deviation/change control and document
control, all in an organized, up-to-date, and easily accessible format. No doubt, IQMS will be key
to maintaining our ISO compliance and moving forward through continuous improvement.
Christensen agreed. During the past several months, weve expanded EnterpriseIQ to manage
all design and development projects as well as implement a preventative maintenance
program, he said. "EnterpriseIQ is intelligent innovation that delivers significant results for WPI.
We just keep asking ourselves why we didnt implement this system sooner.
Here is a focused look at one small part of the EnterpriseIQ system and the difference
two modules can make when they are part of a comprehensive system

A Weekly Manual Affair

Before utilizing IQMS payroll and time and attendance modules, WPI was struggling with the
ABRA Payroll system by Best Software. Unfortunately, the legacy software package was

complicated to use, resulting in only a few people using it, and maintenance costs were
expensive. Tax updates were not timely, the software lacked vacation accrual capability and
getting standard reports of the system was difficult. To top it all off, quarter and year-end close
outs had to be contracted with an outside vendor to ensure everything was completed.
But thats not the worst of it. WPIs former payroll process involved paper-based punch time
cards that were printed out weekly for approximately 230 employees! At the end of each week,
the paper time cards had to be collected, hand tabulated, sorted, totaled and verified. With no
way to adjust for early or late punches, supervisors had to review each time card in detail and
then the time cards had to be manually keyed into a spreadsheet for import into the payroll
system a very time intensive process for the accounting team as well as the supervisors who
were required to spend valuable hours verifying the details.

A Paper Cut
After purchasing the payroll and time and attendance modules from IQMS, WPI participated in
only two one-hour training sessions before they felt comfortable with the package. Because the
IQMS system is comprehensive and all the modules are integrated (rather than third party
disparate packages), WPIs employees immediately felt comfortable with the new modules.
Knowing how to maneuver around the system, rather than having to learn a new interface, is
half the battle.
WPI no longer prints paper-based time cards. They have become completely digital and
employees now sport modern badges complete with a personalized employee barcode and
photo. With just the swipe of a badge, the IQMS payroll and time and attendance modules
automatically adjust the clock in time to correspond to the shift start time.
With the implementation of the IQMS payroll module, I have gained at least a day and a half of
my work week, said Allison Cornelissen, human resources assistant at WPI. When we made
the full conversion to IQMS, I was able to stop the manual entry of hours and process payroll in
a much more efficient manner. The system is so user friendly and easy to learn, I only wish I
had it sooner!

A Seamless Transition
In only three short months, WPI completely paid for the price of the software. WPI was
pleasantly surprised at how easy it was to implement the new modules and was ready to launch
earlier than anticipated. Since WPI had to wait until the quarters end to finish up the legacy
system, they had employees utilizing the new system weeks ahead of time. This parallel system
meant that when the actual go live date arrived, employees saw no change and the first payroll
on IQMS was a seamless transition across all four plants.
Valuable time was WPIs largest area of savings. Before, employees were spending three to
four hours a week printing paper time cards and one to two hours per week keying information
into the legacy system. Supervisors were spending three to four hours per week reviewing time
card details. Today, supervisors only spend one to two hours a week and other employees
tasked with payroll have saved one and a half days (approximately $10,000 per year!)
In addition to the massive time savings, WPI also experienced cost savings. Besides the
environmental benefits, WPI now saves $3,000 per year in paper costs by eliminating paperbased time cards. Maintenance fees for the legacy payroll system were more than $4,000 per

year, and that did not include any integration with IQMS. WPI now pays less than a quarter of
that cost for a better system.
A seamless transition across four plants, cheaper, easier to use and significant time savings
now those are phrases WPI can succeed by.