Case History


Via Spadolini, 5,
20141 - Milano

Tel: +39 02 847841

chairman@colussigroup.it
www.colussigroup.it

Colussi Spa

Food & Beverage


Colussi Group brings together some of the best-known brands in the Italian food tradition - Colussi, Gariboldi 1889, Misura, Agnesi, Flora, Sapori di Siena 1832 - and distributes two leading international brands - Liebeg and Del Monte.

Virtuous brands, selection of excellence and representatives of Made in Italy throughout the world. 

Each of the Group's brands expresses the values encapsulated in Colussi's DNA: the great Italian food tradition, quality as the guiding star, innovation as research, development and dynamism, integrity in action, and respect for consumers, customers, and collaborators.

Products:

WMS

StockSystem

WAREHOUSE LOGISTICS MANAGEMENT

Software for the management of logistics processes.

Colussi Group

Colussi Group's numbers

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Colussi Group is a private Italian business enterprise operating in the food sector.

Its activities include the production and marketing of a full range of high-quality products: pasta, rice, baked goods, and pastries.

PRODUCT AREAS

PRODUCTION SITES

EMPLOYEES

MAIN MANAGED BRANDS

Company

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Colussi Group is a private Italian entrepreneurial reality operating in the food sector.

Starting from the small artisan workshop founded in 1911, and leveraging the constant pursuit of excellence, it has become a solid enterprise that diversifies its activities in the quality food sector, successfully competing in major European markets.

The COLUSSI Group is the second largest pasta producer in Italy, the first in whole wheat pasta, the second in baked goods, the third in cookies, the third in rice, and the first in typical Tuscan products.

Seven of Italy's most excellent traditional brands are part of the Group: Colussi, Misura, Agnesi, Flora, Sapori Siena 1832, Liebig and Del Monte.

A strong presence abroad, beyond Italy, forms the backbone of a company that wants to play a leading role in the international arena with efficiency, flexibility and competitiveness.

Quality without compromise.



With the use of StockSystem, we are able to guarantee the same level of service (availability of packaging and raw materials) with less inventory in stock.

Giovanni Aprato

CIO Colussi Group

NEEDS AND GOALS

The rapid growth of the Colussi Group through acquisitions of different companies generated an increase in complexity. So in the year 2001 Colussi decided to unify its information systems and rely on StockSystem, Replica Sistemi's software for advanced warehouse management.

The objectives of the project were:

  • Obtain reliable and timely information on inventory and warehouse movements
  • Standardize operating procedures
  • Facilitate the outsourcing of warehouses
  • Control warehouse flows in detail
  • Change quality status centrally and independently of product location

ISSUES

The main issues in logistics flow management are:

  • Increased production sites with different technologies
  • Increased items to be handled
  • Increase products marketed
  • Start of production synergies with transfer of some production between sites
  • Different Information Systems
  • Concentration of some activities (procurement, scheduling, transportation)
  • Different distribution realities
  • High number of storage warehouses (Agnesi distribution system was organized with 12 stock points)

SOLUTIONS

After careful evaluation and analysis, it was decided to implement a computerized warehouse management system: StockSystem from Replica Sistemi.

Migration to the StockSystemEvolution application took place in 2010.

The critical points for Colussi were:

  • Physical/accounting consistency of packaging and raw materials warehouses. Accounting unloading of warehouses was done using database values (higher/lower consumption created physical/accounting differences on inventories that were corrected by rolling inventories on a weekly basis)
  • The physical control of inventories and the manuality of entering the accounting movement on the system slowed down the updating of inventories, creating difficulties for the supply office


Weight of activities in the installation of the StockSystem WMS:

  • 60% application integration with management (the difficulty in achieving good integration grows exponentially with the number of contact points between the two systems) pallet status management rotating inventories spot picks automatisms on transfers between internal and external warehouses complete and continuous interactivity between the two systems
  • 30% StockSystem parameterization choice of handling logics, material management criteria (how to transform a manually managed warehouse into a fully computerized warehouse)
  • 10% user training

  • WMS: StockSystem

  •  180 terminals Honeywell 9951 and 5 Symbol MC9090

Initially this was done by doing the analyses related to:

  • warehouse layout
  • materials typology
  • integration with central information system
  • input and storage flows
  • flows of withdrawals and shipments

Involving the following business functions:

PRODUCTION PLANNING

Inventory control by expiration date - lot - status

PRODUCTION

Pouring out-of-line productions to stock

Production activity control (query by item, date, lot, line, ...)

QUALITY ASSURANCE

Pallet status management

Traceability

Centralized management of product blocking/unblocking

Centralized management of disposals

PACKAGING WAREHOUSE

Receipt of Raw Materials/Packages

Management of transfer lists to production lines

Return to warehouse qty not used in department

FINISHED GOODS WAREHOUSE

Production storage

Receipt of marketed products

Management of shipping lists

StockSystem facilitated:

  • Activation of positive release
  • Full traceability of products
  • Use of dedicated procurement and scheduling applications


  • Management of the proper rotation of products by expiration date
  • Management of inventory and constant monitoring of product obsolescence
  • Management of locked-in product awaiting release

It has also allowed us to overcome, in the management of packaging and raw materials warehouses, some difficulties that prevented precise and timely procurement activities.

With the use of StockSystem, it is possible to guarantee the same level of service (availability of packaging and raw materials) with less stock in the warehouse.

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