Howard Johnson’s Enterprises, Inc.
Case Study: Howard Johnson's Enterprises, Inc.
About The Company
Howard Johnson began his company in 1962 with the goal to produce the very best fertilizer products available. Starting out as a small producer of farm fertilizers, Howard Johnson’s Enterprises, Inc. (HJE) has grown and diversified into a leading provider of lawn and garden fertilizer products, for both the retail and professional markets. Today, HJE produces products for Wal-Mart, TruGreen/Chem Lawn, Hardware Hank, Orscheln and others
The Situation
HJE was using a discrete manufacturing package. This package fell short on many aspects. The largest problem was that the package assumed a discrete process. This is a common struggle many true batch process manufacturers have when trying to make a discrete package fit their process-style manufacturing operation. “It’s like trying to make a square peg fit in a round hole,” says Valerie Quarve, ProcessPro National Sales Representative. Along with these operational roadblocks, the software was no longer supported by the vendor. HJE needed specific process manufacturing software from an established and experienced vendor who understood their industry
The Solution
HJE hired a Manager of Accounting and IS specifically to upgrade their networks and to evaluate and select a new manufacturing software. Constructing a committee of approximately 8-10 employees from different areas of the company, HJE evaluated 6-7 software packages. Because they knew the shortcomings of discrete packages in a process environment, they only considered true process-based software packages during the evaluation process. After a high-level review, the search was narrowed down to 3 packages and vendors were given the opportunity to present their software to the group.“ProcessPro put the most effort into addressing our unique needs,” comments Cindy Gibbs, Manager of Accounting and IS for HJE. The committee vote was unanimous: ProcessPro® software was clearly the best ERP package for HJE’s needs. From the start of the selection process to the Go Live
date, the ProcessPro/HJE team completely implemented a new ERP system in only 8 months. “This is a very aggressive timeline when you are talking about full ERP system implementation with custom,” says Steve Gagne, Project Manager. HJE had a very firm timeline. “The ProcessPro staff worked very hard to get HJE up and running within the desired timeframe,” said Gibbs. “We feel it was a great success.” Howard Johnson’s philosophy of manufacturing to the highest standard remains the cornerstone of their family owned business. ProcessPro® software has been instrumental in providing the proper business tools to help HJE effectively and efficiently carry out their operations and uphold their high standards.
Benefits & Results
Understand “process” Environment
HJE was using a discrete package that did not understand the process manufacturing environment. It did not account for necessary procedures specific to this type of manufacturing. ProcessPro software was designed with the help of industry experts and front-line managers within the process manufacturing industry. This ERP is a true process manufacturing software accounting for all their specific needs. Also sold with source code, it is 100% customizable
Custom Formulator
HJE sales reps receive requests for formulations from customers over the phone. HJE’s previous software did not have a way to check current formulas to determine if they met the customers’ requirements, consequently multiple formulas were created for the same formulation thus slowing the system and creating confusion. Sales reps are able to enter the customer formulation requirements directly as they are talking to a customer. The software finds any current formulas that match. If a formula is found, it may be used as is or repackaged in a different size. Also, new formulas may be created and tested to the customer specs. Costs and markups are calculated and customers can be given prices immediately
Easy to use: Order Entry System
HJE’s previous order entry system was not integrated with their quoting system, as a result customer quotes had to be looked up individually and the information manually entered on the sales order. Fully integrated with the new formulator software, ProcessPro software’s order entry system automatically transfers all quotes to a sales order when approved. Total weight and number of pallets is displayed on the sales order entry screen to facilitate optimum shipping schedules
Optimized Batch Size
HJE’s mixers have minimum and maximum quantities they can handle. The staff needs to calculate the number of batches and the size of each batch when filling an order. ProcessPro software uses the minimum and maximum batch size for each mixer to determine the smallest number of batches needed to fill an order where the size of all batches falls within the required weight range.
Guaranteed Analysis
HJE needed to report trace elements on the guaranteed analysis tags for each product. By using the chemical properties of the ingredients listed on the bills of material, in combination with industry and Department of Agriculture requirements, any reportable trace elements and additives automatically print on the guaranteed analysis.
EPA Registration
The chemicals within some of the products HJE sells must be registered according to each state’s requirements. Some products are allowed while others would not meet the state regulations. Process Pro software tracks product registration requirements for all products throughout each state. When a sales order is taken, the software automatically verifies the products that are registered, eliminating the need for any manual verification
True MRP
All scheduling was previously done manually. This posed problems with purchasing. HJE needed a true MRP system. ProcessPro software provided an MRP system that allowed efficient and accurate scheduling without becoming too complicated for the users
Integrated Business Software
ProcessPro software is a completely integrated ERP system, from sales order entry, through manufacturing, shipping, and the accounting process. Software was needed that best fit their manufacturing process was the #1 priority, but HJE also needed a financial package that would meet their needs.
Established Software Vendor and Solid Product
HJE’s previous software was more than a decade old. They no longer received upgrades or support from the vendor. HJE was also looking for a nonproprietary database with flexibility. Backed by a company with over 2 decades of experience in the IT field, ProcessPro software rises above other industry leaders in financial integration, functionality, user compatibility and more
