Berlin Gardens ERP Case Study

Industry

Furniture

Challenge

Berlin Gardens faced operational complexity due to fragmented scheduling, inefficient inventory management and time-consuming duplicate data entry. With high order volumes and limited production space, meeting tight lead times and controlling raw materials inventory required a more sophisticated, integrated solution.

Results

By implementing Global Shop Solutions ERP, Berlin Gardens achieved a 20% reduction in raw materials inventory, cut furniture lead times to 2 weeks and saved 20 minutes per work order through automation. The centralized system improved on-time delivery, enhanced cost tracking and enabled efficient job customization, supporting lean Six Sigma practices and positioning Berlin Gardens as a more agile, competitive manufacturer.

Key Applications

Inventory, Advanced Planning & Scheduling, Accounting, Bill of Materials, Product Configurator, Tailored ERP

berlingardensllc.com/

20%

Raw Materials Reduction

Minutes Saved Per Work Order

centralized system

Managing Berlin Gardens with one integrated system has improved how we work together as a company. Global Shop Solutions has us working together, communicating better and all moving in the same direction to deliver quality products that our customers can use to enjoy the great outdoors.

Owen Yoder

IT/Systems Manager

About Berlin Gardens

Founded in 1988 and headquartered in Berlin, Ohio, Berlin Gardens manufactures outdoor living products, including outdoor structures and poly furniture like chairs, picnic tables, benches and arbors, combining old-world craftsmanship with modern technology.

The Challenge

Before adopting Global Shop Solutions ERP, Berlin Gardens struggled to manage production complexity. Their legacy business management system created challenges in scheduling work orders, controlling inventory and reducing duplicated data entry. With a growing demand for high-quality outdoor furniture and limited production space, the company needed to optimize inventory, accelerate lead times and respond effectively to customer orders, all while maintaining cost efficiency and product quality.

The Solution

Berlin Gardens evaluated its options and selected Global Shop Solutions ERP for its comprehensive, integrated features. The decision was driven by the need for a system that unified inventory control, accounting, scheduling and order management. Owen Yoder, IT/Systems Manager at Berlin Gardens, shared: "Our biggest challenge was the way we scheduled work orders. We wanted a one-stop shop with inventory control, accounting, scheduling and everything else, and Global Shop Solutions offered an all in one integrated system." The implementation provided Berlin Gardens with real-time visibility into job requirements, automated work order creation and advanced scheduling capabilities. As Yoder explained, "With Global Shop Solutions, we have complete visibility of all job requirements. This allows us to produce exactly the amount of pieces on order, which helps get the product out the door on time." The product configurator module further simplified order entry and customization: "When entering an order, we simply select the options and Global Shop Solutions creates the material list, generates the work order and schedules everything – saving about 20 minutes per work order."

The Results

With Global Shop Solutions ERP in place, Berlin Gardens realized measurable improvements: a 20% reduction in raw inventory, a consistent two-week lead time for furniture and a time savings of 20 minutes per work order. The ERP's robust reporting and analytics supported better cost tracking, while the integrated environment facilitated lean manufacturing and improved internal collaboration. Berlin Gardens maintained peak order fulfillment at 25 orders per day, ensuring timely delivery and high customer satisfaction. Yoder affirmed, "Managing Berlin Gardens with one integrated system has improved how we work together as a company. Global Shop Solutions has us working together, communicating better and all moving in the same direction to deliver quality products that our customers can use to enjoy the great outdoors."