Next production facilities Synthos S.A. increase productivity with WMS Optipromag®

In order to effectively manage its warehouse processes, the Synthos Group decided to cooperate with Optidata. The initial implementation of the WMS OPTIpromag® system took place in 2011. Due to the company’s growth, the need to increase efficiency, and the desire to maintain a competitive advantage, the Synthos Group decided to adapt and implement the WMS OPTIpromag® system in other Group companies. The implementation of the new system and the update of the existing one took place simultaneously across three locations: in Poland (Dwory and Agro) and in the Czech Republic (Kralupy). An additional challenge was the concurrent implementation and launch of the SAP system. Deploying two such large IT systems simultaneously was a major undertaking.

Synthos Dwory operates in the production of synthetic rubbers and latexes, polystyrene (PS) and expandable polystyrene (EPS), XPS insulation boards, as well as vinyl and acrylic dispersions and wood adhesives. The WMS OPTIpromag® system has supported warehouse and production processes at this site for 8 years. During the recent implementation, the latest software version was launched.

At the Kralupy plant, the Czech counterpart of the Dwory plant, the WMS OPTIpromag® system was implemented from scratch. A significant change was the transition from the previously used offline solution to the real-time WMS OPTIpromag® system.

The updated version of the WMS system is also in use at another Synthos company, AGRO, which supplies plant protection products. Within the WMS OPTIpromag® system, great emphasis was placed on optimizing storage strategies that ensure even distribution of inventory on mobile racks while maintaining proper separation of specific chemical components.

The WMS OPTIpromag® system covers many areas, including production receipts, labeling (according to GS1 and Odette standards), placement of goods in the warehouse, handling of logistics unit/batch blocks, and parameter control. Additionally, the software enables the generation and printing of quality certificates, releasing goods to customers, and managing Goodpack packaging.

One of the key requirements for the WMS OPTIpromag® system in Synthos Group plants was the management of quality parameters. These parameters are among the main criteria for selecting batches of products delivered to recipients. The implemented system is integrated with the SAP system for information exchange regarding quality parameters. The parameters registered in SAP are transferred to the WMS system, which links them to inventory and then uses them during issuance to select the optimal batch for the customer.

The entire implementation was successful, as confirmed by achieving over 98% operational capacity immediately after system launch.

• Automation and increased efficiency of logistics processes
• High-quality customer service
• Improved goods receipt processes through integration with labeling machines on production lines
• Effective quality control management

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