Forma-Fab Metals, Inc. ERP Case Study

The Challenge

Forma-Fab Metals was experiencing rapid growth but struggled with fragmented operational processes. The company depended on spreadsheets and manual tracking for inventory, production scheduling and job costing. These disjointed systems resulted in inefficiencies, reduced visibility and delays in responding to customer needs, making it difficult to maintain quality standards and prepare for continued expansion.

The Solution

Recognizing the need for a unified ERP system, Forma-Fab Metals evaluated their options and chose Global Shop Solutions for its comprehensive manufacturing capabilities and real-time business intelligence. The decision was driven by the platform’s ability to centralize all aspects of their operations, from advanced planning and scheduling to inventory control and financial oversight. According to Ron Tedder, Director of Operations, "APS gives us a lot of flexibility in how we manage our production schedules. The visual aspects make it easy to absorb and understand all the data. When it comes to scheduling, Global Shop Solutions is head and shoulders above everyone else." The team rapidly adopted modules for production management, job costing and integrated shipping and invoicing, which provided immediate improvements in accuracy and efficiency. Founder Richie Richmond noted, "With Global Shop Solutions, we discovered that shipping parts under the same system in which they are invoiced eliminates those ‘black holes’ where some parts get shipped but never get invoiced. You always want to get paid for what you ship, so I was really happy to see improvement in that area."

The Results

After implementing Global Shop Solutions ERP, Forma-Fab Metals realized dramatic operational gains. Finished goods and work-in-process inventory were each reduced by 50%, while raw materials inventory was cut by 20%. The company, supported by a team of 30 machinists, leveraged the ERP’s robust job costing and analytics features to track margins and profitability at the part and customer level. Richie Richmond described, "We can track job costing, margins and profitability – for every part, for every customer – with amazing precision. If we start getting squeezed by competitors, we can identify areas where we can safely take less margin and still make money." Enhanced visibility and automation also improved customer service and responsiveness. Backed by real-time data and centralized workflows, Forma-Fab Metals is now positioned for scalable, efficient growth.