Orapi UK manufactures products for the automotive, metal treatment and janitorial sectors, supplying major customers including Toyota, Jaguar Land Rover, JCB, Howdens and Wren Kitchens.
Ahead of its move to a new manufacturing and distribution facility, the business identified an opportunity to modernise the way stock was managed across its operation.
Previously, Orapi relied heavily on paper-based processes and the knowledge of individual employees to locate stock.
Although quantities and values were recorded, the system did not always provide visibility of where inventory was physically located, often leading to avoidable downtime.
Orapi operations manager Karl Parsons said: “People would say, ‘we haven't got the stock’, but realistically it was more to do with not being able to find the stock.”
Rather than transfer existing processes into the new facility, Orapi partnered with Portech to introduce barcode-based warehouse management as part of the relocation.
Portech worked closely with Orapi’s operations and IT teams, as well as its mainframe provider, to map the new warehouse, establish stock locations and integrate the new processes with existing systems.
The full implementation was completed within six to eight weeks.
Today, warehouse operators use handheld scanners that direct them to the correct stock location. Stock movements are recorded instantly, giving the business far greater real-time visibility of its inventory and significantly reducing downtime.
Karl said: “The amount of downtime has reduced enormously because people know exactly where they're going.”
The new system also provides a foundation for further operational improvements. Orapi’s next planned development is perpetual inventory, enabling stock counting to take place throughout the year while the business continues operating, rather than requiring a shutdown for an annual stocktake.
Portech recently shared the project in a customer webinar, where Karl discusses the challenges Orapi faced, the implementation process and the results achieved.
Karl added: “I would recommend Portech. Where we needed further modifications added to the system to help us with our working life, it was done, and it was done quickly.”
The webinar is available from Portech for businesses looking to improve stock visibility, accuracy and efficiency within their own warehouse or manufacturing operations.
