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Thomas Instrument ERP Case Study

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Industry

Government Contract

Challenge

Thomas Instrument, a Texas-based manufacturer serving the U.S. Department of Defense, managed 300-400 active work orders at any time and faced significant challenges due to manual work order processing, inefficient labor tracking and complex change order management. These obstacles led to delays, errors and difficulty meeting strict on-time delivery and quality requirements, all within a manufacturing environment that demanded precise scheduling, rapid response to production issues and regulatory compliance.

Results

After implementing Global Shop Solutions ERP software, Thomas Instrument automated move ticket processing, improved the precision of labor time tracking and integrated real-time dashboards for enhanced visibility. These advancements led to measurable reductions in defects per million opportunities (DPMO), lower cycle times and faster response to scrap and rework. With a 2-hour inspection wait threshold and a 100-day scheduling window, Thomas Instrument saw a significant improvement in on-time delivery, data accuracy and overall production efficiency across their manufacturing operations.

Key Applications

Advanced Planning & Scheduling, Shop Floor Data Collection, Quality Control, Company Messaging, Dashboards, Integrations, Shop Management, Tailored ERP

www.thomasinstrument.com/
100%
Data Entry Reduction
25%
LOWER DEFECTS PER MILLION OPPS
20%
Faster Scheduling

Global Shop Solutions is a very comprehensive ERP package. From the Shop Floor Data Collection stations that track labor and machining time with great precision to shop scheduling, automated move tickets and more, the software does everything you want it to. It has made a huge difference in every area of our business.

Mike Slamen

IT Manager

testing

About Thomas Instrument

Thomas Instrument is a Texas-based company with over 30 years of experience providing engineering, manufacturing and repair/overhaul services to the U.S. Department of Defense. The company produces and services parts for defense aircraft, including F-15 and F-16 fighter jets and holds certifications such as AS9100RevC and FAA Repair Station approval.

The Challenge

Thomas Instrument faced critical operational challenges as they supported complex assemblies for fighter jets like the F-15 and F-16. Managing 300-400 active work orders concurrently, the company struggled with manual work order processing, labor-intensive tracking systems and cumbersome change order management. These manual approaches introduced delays, increased the risk of errors and made it difficult to maintain strict quality and delivery standards required by their customers and industry certifications.

The Solution

Recognizing the need for a more automated and integrated approach, Thomas Instrument evaluated their options and selected Global Shop Solutions ERP to modernize their operations. The ERP system was chosen for its comprehensive functionality, ability to integrate with third-party applications and real-time data capabilities. As Mike Slamen, IT Manager at Thomas Instrument, shared: "With Global Shop Solutions, move tickets are faster and more accurate than the traditional barcoded work order. Machinists hit a few keys, the ticket gets printed and they slap it on the pallet. When they log out of their sequence, everything is ready to go." The team also leveraged the manufacturing Dashboard, which, as Slamen notes, "provides a detailed look at the whole shop floor. One of the real benefits of Global Shop Solutions is its ability to work with other programs. We create the dashboards in Excel, connected directly to the database." By utilizing Shop Floor Data Collection stations and automated scheduling, Thomas Instrument achieved a higher level of control, traceability and efficiency in their production processes.

The Results

Implementing Global Shop Solutions ERP delivered substantial operational improvements for Thomas Instrument. The automation of move ticket processing, enhanced labor and machining time tracking and seamless dashboard integration empowered the company to reduce cycle times and defects per million opportunities (DPMO), with DPMO rates declining compared to the previous year. Inspection wait times were reduced to under 2 hours, scheduling visibility expanded to a 100-day window and the company maintained 300-400 active work orders with greater precision and efficiency. These measurable outcomes led to better on-time delivery and faster response to production issues.

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