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FG Wilson, a wholly-owned subsidiary of engineering giant Caterpillar, employs some 2,000 employees at its Larne manufacturing plant north of Belfast. The company produces diesel- and gas-powered electricity generators and exports 99 percent overseas. But the firm found that producing manuals for its products difficult to manage.
FG Wilson's challenges included the need to:
- produce operating manuals in different languages while keeping up with changing technology and new models
- meet regulatory requirements to print manuals in every language of the European Union and in other widely spoken languages
- streamline the printing and collating process and reduce waste levels
- improve quality control on manual packs to insure they include accurate information in the correct language.
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To meet FG Wilson's challenges, Xerox devised a strategy to:
- allow the company to retain control of the printing facility in-house in a cost-effective and flexible manner
- tailor a Xerox DocuTech™ hardware and software solution to move existing document processes to a Just in Time system
- redesign the manual pack for optimal production, digital printing and finishing
- enable order input from a customer's SAP system, so the bill of materials can be sorted according to order number, manual type and language.
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The Xerox solution produced the following benefits for FG Wilson:
- increased productivity by 100%
- redeployed staff and eliminated obsolete stock
- delivered annual savings of £250,000 in its first year
- improved customer service due to more timely delivery of complete manual packs.
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