CASE STUDIES

POL-MAK

Multi-plant POL-MAK integrates,
automates whole organization

The Query

Pol-Mak needed an end-to-end solution that spans the entire scope of the organization.

POL-MAK is an international producer of napkins, paper plates and cups, decorative bags, giftwrapping paper, greeting cards, as well as tissue paper. POL-MAK is a family business in the decorative stationery industry, producing products for over 35 years. In 2017, POL-MAK added a large production facility and has a total of three plants and an extensive system of warehouses.

The company had a combination of disparate and siloed systems and was trapped in an array of manual processes and inefficiencies that stymied the company’s growth ambitions and increased the risk of mistakes in estimating, scheduling, and planning departments.

According to Dariusz Makowiak, co-owner of POL-MAK, “We wanted to have a proven IT system that helps efficiently and reliably manage the entire production cycle of the company.”

PRODUCTS

Paper products – plates, cups, napkins, tissue paper, greeting cards

MACHINES

Heidelberg Speedmaster CD 102-5 machines, in B1 format, 11 flexo printing machines

COMPANY size:

90 + employees

Location:

Przeźmierowo, Poland

The challenge

Disconnected systems and manual processes hindered Pol Mak’s growth.

Before implementing HiFlow’s software, POL-MAK faced significant operational challenges. The company struggled with a lack of unified systems and relied heavily on manual processes like printed papers, planning boards, and Excel spreadsheets.

This outdated approach led to slow operations, lack of real-time feedback, and frequent errors, particularly in production and prepress, where 12 graphic designers managed graphics without efficient digital tools. Pol Mak needed to replace a system based on Excel that had previously been driving estimating, scheduling and planning departments Makowiak comments, “Such ‘blind’ work generated errors and mistakes in the production process.” The company needed a robust system to enhance precise cost estimations, integrate operations across various locations, and improve overall workflow efficiency without exponentially increasing staff numbers.

“I can certainly say that thanks to HiFlow, our company now bypasses any previous manual processes and we efficiently manage our entire production cycle.”

The solution

POL-MAK automates and integrates with a modern efficient system that allows them to scale.

The company needed a robust system that provided precise cost estimations, integration of operations across various locations, and improve overall workflow efficiency without exponentially increasing staff numbers.

HiFlow’s comprehensive software solution provided POL-MAK with advanced tools for multi part quoting and detailed estimations that their clients valued highly. The system’s capacity to template estimates significantly streamlined the quoting process, enhancing customer satisfaction with rapid and accurate responses.

Implementation of HiFlow allowed for significant internal reorganization and expansion of departments, optimizing the workforce without the need for excessive hiring. Makowiak notes, “With the expansion of our company’s structure and an increase in sales, we hired more personnel. Without the implementation of the system, we would have had to hire even more people.”

Automation and precise parameter definitions within the system drastically reduced operational errors. “The number of errors in our company has certainly decreased. By automating processes and defining the work parameters in the system, we have made significant progress in this respect.”

Staff productivity increased due to system-induced efficiencies, with automation saving considerable time. “We also found that staff productivity per capita increased. In addition, staff can see how much the system improves their efficiency and how much time is saved by automation.”

HiFlow’s sophisticated scheduling tools effectively managed both offset and flexo presses across all locations, synchronizing production activities and optimizing resource use. POL MAK needed scheduling that would handle both offset and the flexo presses in all its locations. HiFlow’s production planning, combined with its scheduling tools, have algorithms that can schedule offset and the flexo departments as well as synchronize all production activities in all company locations at the same time.

HiFlow’s solution not only fortified POL-MAK’s operational capabilities but also empowered them to scale their business effectively while maintaining high standards of quality and customer satisfaction. The software’s integration and real-time data capabilities provided a solid foundation for continued growth and efficiency. “I appreciated the scope and complexity of the new system, the high degree of automation of production activities, and its exemplary transparency.”

“The number of errors in our mcompany has certainly decreased. By automating processes and defining the work parameters in the system, we have made significant progress in this respect.”

Takeaways

Sophisticated estimating engine

HiFlow’s powerful estimating system is able to turn an inquiry into an estimate in just a few clicks using the modules within the HiFlow system.

Connect to HiFlow’s live data network. Instantly see accounts, past quotes, shipping info, inventory levels, and vendors-in real time.

“Creating quick and precise calculations is undoubtedly a serious advantage of the system’” reflects Makowiak. HiFlow offers the option of presenting clients with a multi- part quote. Estimates can be templated to provide a great deal of detail, which POL- MAK’s customers appreciate.

Increased customer satisfaction

Ensure customer success with a single customer view that enables CSRs to provide better communication. And customers can use HiFlow’s Customer Portal that allows them control of their job from initial inquiry through production and final delivery.

After the system’s implementation, POL-MAK’s clients received faster and more complete communication enhancing the total customer experience.

“I appreciated the scope of operation and complexity of the new system, the high degree of automation of production activities, and the exemplary transparency.”

Insightful business intelligence

Makowiak appreciates the incredible amount of data HiFlow’s business intelligence provides. HiFlow’s Reporting and Business Intelligence modules access the vast amounts of raw data available throughout the entirety of your business and production landscape.

“With HiFlow’s business intelligence and analytics we know a lot more about the company itself.” With the real time data the system provides, “We can react faster, and very precisely, to both typical and unusual situations in the plant.”

Increased productivity; labor costs saved

HiFlow provided the means to expand POL-MAK’s organization. As workflow efficiency increased, it allowed POL-MAK to reorganize and enlarge some departments in the company. Makowiak notes, “With the expansion of our company’s structure and an increase in sales, we hired more personnel. Without the implementation of the system, we would have had to hire even more people.”

“We also found that staff productivity per capita increased. In addition, staff can see how much the system improves their efficiency and how much time is saved by automating the most time-consuming activities.”

The Benefits of Partnering
with HiFlow Solutions

We implement – fast. The HiFlow system combines MIS and MES software with easy ERP integration.

We fill your ERP gaps. By optimizing ERP systems with MIS and MES features required for packaging and label printing.

We create automated environments. With seamless connections from order intake to shipping and invoicing.

We feed you data. With insights from real time, critical information from your production shop floor, personnel, and equipment.

We let you see. From smart scheduling to nested layouts to workflow diagrams, instantly see where you stand within the job.

Do you have additional questions about implementation? Contact our experts to discover how HiFlow System can help address your company’s challenges.