Bonnell Aluminum reported it achieved improved operational results and more manageable KPI reporting after using the software

December 14, 2021

MORRISVILLE, N.C.—Custom extrusions manufacturer Bonnell Aluminum reported that it improved its quality and productivity, while achieving the best safety record in its history, after working for nearly a year with Dploy Solutions Strategy Deployment software. Benefits of working with the software included transitioning from cumbersome spreadsheets to a more streamlined process of tracking and managing KPIs aligned with strategic goals, according to a release from Dploy Solutions, a developer of digital manufacturing and industrial IoT software.

Throughout its five manufacturing facilities, Bonnell Aluminum has developed products, processes, and culture that align with its key values and Operational Excellence (OpEx) mindset. But it wasn’t until 2019 that the company discovered the need to broaden the scope and improve the effectiveness of its existing processes, according to the release.

At the time, the entire company was using spreadsheets to track and manage OpEx initiatives. Each facility was tracking progress against its own goals that may or may not have supported the overall long-term strategy of the company. Because Bonnell was using different systems that remained following acquisitions, the performance of individual facilities was presented in various formats via monthly reports. In addition, performance was also not always measured consistently.

Bonnell decided that the fix would require the ability to easily cascade specific goals, see linkages between daily management and the impact on strategic goals, and gain visibility at every level and location. The entire process would have to be on a single platform that everyone could access and manage without creating layers of work and administrative tasks.

As Bonnell Aluminum began implementing Dploy Solutions Strategy Deployment software, the Dploy Solutions team provided customized training, quick response time to any questions that arose, and clear guidance around policy deployment needs, according to the release.

Dploy Solutions is a digital manufacturing and industrial IoT platform that is said to connect,  visualize, and analyze data “from the top floor to the shop floor.” It was developed to help “small- to mid-sized companies move down the digital manufacturing path and create value from technology investments while taking Lean and Continuous Improvement to the next level,” the company said in the release.

Using Dploy Solutions, Bonnell Aluminum had fully transitioned, by 2020, from spreadsheets to its new digital policy deployment processes. This created uniformity across the organization on how teams viewed and executed the company’s vision, while simultaneously improving the effectiveness and use of policy deployment and OPEX resources.

“Dploy Solutions has been a true enabler of our Operational Excellence culture,” said Jason Ward, director of operational excellence at Bonnell Aluminum, in the release. “While COVID affected our operations, we had true organizational alignment around our goals and achieved items such as our best safety record in the history of the company, improved operational results, such as a 2 percent overall yield improvement, and reduced customer returns.”

Nearly a year later, Bonnell Aluminum’s policy deployment process continues to improve while using more of the tools provided by Dploy Solutions. All spreadsheets used for policy deployment purposes have been terminated, and the company is said to be looking ahead to migrate to Dploy’s newer KPI Management capabilities for an enhanced data integration process.

“When the entire company can see measured progress toward company goals, accountability increases and improvement becomes more meaningful,” said Ken Koenemann, vice president of technology and supply chain at Dploy Solutions and TBM Consulting, in the release. “We’re proud to help companies like Bonnell Aluminum make better business decisions by connecting daily improvement initiatives to longer-term strategic objectives and goals.”

Bonnell Aluminum, a subsidiary of Tredegar Corporation, is a manufacturer of custom-fabricated and finished aluminum extrusions. The company serves the building and construction, automotive and transportation, consumer durables, machinery and equipment, electrical, and distribution markets. Its manufacturing facilities are located in Newnan, Georgia; Carthage, Tennessee;  Niles Michigan; Elkhart Indiana; and Clearfield, Utah.

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