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Metalform ERP Case Study

metalform-1

Industry

Metal Fabrication

Challenge

Metalform, a global sheet metal processing and fabrication company, faced significant operational challenges due to managing thousands of unique components and complex production jobs using spreadsheets and disconnected software. Manual, paper-based job packs hindered real-time visibility and control, while slow bill of materials (BOM) creation and lengthy repeat work order processes created bottlenecks that limited efficiency and scalability. Production scheduling was constrained by a lack of integrated data, making it difficult to optimize resource allocation and meet customer demand.

Results

By implementing Global Shop Solutions ERP, Metalform eliminated paper from the shop floor, automated BOM creation and dramatically reduced the time required for repeat work orders. The company achieved a 10% gain in material utilization, reduced BOM creation to just one hour per day and enabled rapid generation of repeat work orders in only five minutes. Real-time data and fully integrated processes empowered sales to schedule more effectively, increased production accuracy and reduced operational errors, supporting Metalform’s continuous improvement and growth objectives.

Key Applications

Advanced Planning & Scheduling, Quality Control, Bill of Materials, Dashboards, Nesting Interface, Paperless, Project Management, Purchasing

www.metalform.co.nz/
10%
Material Utilization Gain
1
Hour BOM Creation
100%
Data Entry Reduction

With Global Shop Solutions, every component now has its own work order. This allows us to concurrently process different jobs, which has dramatically improved production efficiency and reduced work in progress.

Campbell Easton

Managing Director

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About Metalform

Metalform is a family-owned sheet metal processing and fabricating business founded in 1961. Headquartered in Dannevirke, New Zealand, Metalform provides contract manufacturing services and make-to-stock products for customers worldwide, with offices in New Zealand, Australia and the United States.

The Challenge

Metalform managed a high volume of unique components and complex manufacturing jobs. Their reliance on manual spreadsheets and disparate software created data silos, delayed information flow and made it challenging to maintain accurate job packs. Paper-based processes hindered efficiency, while building BOMs was a time-intensive, full-time task. Repeat work orders required significant manual effort and limited production visibility restricted the ability to optimize scheduling and resource allocation. These challenges constrained Metalform’s ability to scale and maximize efficiency in a competitive manufacturing environment.

The Solution

Seeking to modernize operations, Metalform evaluated ERP options with a focus on robust functionality and direct access to the software developer. According to Campbell Easton, Managing Director, "We chose Global Shop Solutions primarily for its robust functionality and knowledgeable sales people. We also liked the fact that we would be dealing directly with the developer of the software rather than a reseller or other third-party vendor." Implementation of Global Shop Solutions ERP enabled Metalform to automate routine processes, integrate shop floor and administrative functions and transition to a paperless environment. The ERP’s nesting integration was particularly valuable: "The nesting integration manages the whole process, including the cutting time and material issuing, so it saves time and money," noted Easton. BOM creation, previously a resource bottleneck, was transformed. As Easton described, "Previously, building our BOMs required more than a full-time role for one person. It now takes about one hour per day and is no longer a constraint."

The Results

With Global Shop Solutions ERP fully deployed, Metalform achieved measurable improvements in manufacturing efficiency and process automation. The company realized a 10% material utilization gain and now manages 5,000 jobs on the shop floor with real-time data access. BOM creation was reduced from a full-time role to just one hour per day, freeing resources for higher-value tasks. Repeat work order creation dropped to only five minutes, accelerating responsiveness and throughput. "I have recommended Global Shop Solutions to several business associates in large part because of their customer service," Easton shared, underscoring the value of the partnership. The ERP system’s integrated approach empowered Metalform to optimize scheduling, reduce errors and maintain a competitive advantage in global contract manufacturing.

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