THE COMPANY
Lyco Manufacturing is a world-class original equipment
manufacturer (OEM) of commercial cooking and cooling
machines, liquid-solid separation screens, root crop
peelers/scrubbers, and snap bean equipment for the
commercial food industry. Located in Columbus, Wisconsin,
Lyco Manufacturing is a single campus with over
75 employees.
THE CHALLENGE
Lyco Manufacturing relied on a legacy system that suited their business for years. However, when a new
controller joined the team, they quickly identified significant inefficiencies, particularly the long lead times
associated with costing. Known for its commitment to innovation, Lyco recognized the need for an
upgrade and engaged a selection consultant to guide them in finding a modern ERP system.
Following a selection process, Lyco engaged a new ERP service provider for implementation. After working
with the provider for about nine months, the limitations of both the service provider and the selected ERP
system became evident:
Limited Understanding of Manufacturing Methods:
The new ERP system adapted well with Lyco’s
contract manufacturing division in areas related to food processing machinery, but functional gaps
emerged when it came to their discrete manufacturing. A team restructuring occurred three months
before the go-live date, requiring a delay and reeducation on existing processes and goals.
e Ineffective Integration with Existing Workflows. Little to no customization was available, requiring the
team to adjust business processes to fit the ERP. The ERP could not accommodate a well-established
costing process developed over 40+ years. Once implemented, additional inefficiencies between
materials management and operations on the floor emerged. Process automation was limited, and the
ERP further created silos between departments.
Inadequate Employee Training:
The manual provided was complex and challenging for employees to
engage with. The training focused on more technical details than practical, everyday applications.
Employees lacked clear guidance on performing routine functions in the ERP. The system’s overall
effectiveness was impacted from the start, causing a loss of confidence in the data received from the
ERP.
Increased Costs Associated with Implementation:
Demands quickly exceeded initial expectations. Lyco
encountered multiple launch delays. In addition, six additional employees were hired to manage the
ERP’s finance functions, and existing staff were assigned additional responsibilities post-launch.
After four years of ERP challenges, Lyco reengaged Guardian
Business Solutions, whose knowledge of Lyco’s operations
proved invaluable. Following a comprehensive evaluation, Guardian recommended Infor CloudSuite Industrial powered by
Syteline. The challenge was introducing this new system,
rebuilding employee trust, streamlining processes, and resolving
previous rollout issues.
THE SOLUTIONS
