Case History

S.P. 37 Conversano - Castiglione, Km. 0,700
Z.I, 70014 - Conversano - BA

Tel: +39 080 4959823

info@masteritaly.com
http://www.masteritaly.com

Master Italy Srl

Mechanical industry, Furniture Complements & Construction


Since 1986, the Master Group has been designing and manufacturing high-tech accessories and components for aluminium windows and doors, investing in the quality of materials, advanced research and technologies, and producing 97% of its production in-house. 

As a leading brand, Master Group is focused on the development of new international markets, attention to safety, sustainability and quality of its products, continuous improvement and waste reduction according to the principles of lean manufacturing, as well as the implementation of the new industrial automation model Industry 4.0.

The company currently occupies 30,000 square metres of covered and 70,000 square metres of open space at the Master Italy site in Conversano (Bari), with a total of over 60,000 references. The market is currently divided into 52% exports to 50 countries worldwide and 48% domestic.

Products:

WMS

StockSystem

WAREHOUSE LOGISTICS MANAGEMENT

Software for the management of logistics processes.
TMS

TMS

TRANSPORTATION MANAGEMENT SYSTEM

Software for controlling transportation costs.
Felice Lembo - Chief Operations Officer Master Italy

Logistics Experience - Master Italy

Interview to Felice Lembo - Chief Operations Officer Master Italy

The numbers of Master Italy

Leader in the production of accessories for window frames.

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The market is split between 52% export and 48% domestic.

thousands managed References

thousands square Metres

Production Departments

thousands of Finished Products

Countries

Employees

Needs

Since 1986, the company has grown rapidly and, more than 10 years ago, the need arose to manage and know in real time the stocks of all production in order to guarantee a level of service to customers who were becoming increasingly demanding in terms of punctuality of delivery.

The choice

Master Italy has taken a significant step towards optimising its logistics flow thanks to the recent strategic expansion and redesign of its warehouse space, but above all by implementing integrated WMS and TMS systems.

Production

Replica Sistemi’s Warehouse Management System interacts with the ERP and MRP to manage production orders and line replenishment:

  • the organisation and standardisation of stock positions in production departments dividing between stock and line replenishment;
  • the management of the input and output docks of the production departments;
  • the management of the quality control dock in each department;
  • the recall of components required for production with picking list;
  • the fragmentation of loading units to maintain the traceability of each component;
  • rapid production order placement by firing the barcode;
  • the real-time unloading of components in backflush;
  • the possibility of modifying the production order list;
  • the management of rotating inventories;
  • departmental KPI analysis: no. of codes inventoried per week, no. of movements per hour.

Distribution

Once the production process is complete, the WMS takes charge of the finished product and organises:

  • the management of the 3 types of pallet types (inner pallet, middle pallet, parcel), according to the volume of the article;
  • the use of the «storage» function according to product families;
  • the use of the topping-up strategy during storage to minimise picking points and maximise warehouse saturation;
  • the management of picking zone and stock area on the shelf;
  • definition of maximum and minimum picking quantities per article;
  • the management of «lowering» from stock zone to picking zone.

In addition, the Warehouse Management System integrates with the Transportation Management System. Once the order is ready to be shipped, the WMS sends the delivery data to the TMS, which:

  • checks all characteristics (weight, volume and destination);
  • compares carriers’ rates;
  • indicates the most convenient carrier;
  • it also allows you to check and control the cost of transport by issuing pre-invoices.
Magazzino Master Italy

Advantages of using the WMS

In logistics, the use of the WMS has brought very important results, such as:

  • the elimination of code exchange errors during picking;
  • an increase in productivity (movements/hour) of +50%;
  • the zeroing of empty location search times to store the product.

Vantaggi WMS e TMS integrati

Integrated WMS and TMS

In general, the advantages gained by Master Italy from the use of integrated WMS and TMS of SMA.I.L:) platform are:

  • implementation of weight control before goods exit;
  • real-time evidence of rates for single shipment based on weight and volume and very quick choice of the most convenient one;
  • drastic reduction of the errors of loading means;
  • possibility to implement statistics by route or type of transport used;
  • possibility of creating KPI on shipment flow;
  • management of carrier pre-invoices for invoice control.

Managing the complexity of production processes with smart Warehouse Management System solutions has been the key to the success of the collaboration with Replica Sistemi. The WMS, combined with TMS, allows us to achieve goals of excellence. 

We are sure that Replica Sistemi will be able to accompany us in the future, for our international logistics project, just as it has done very well during the evolution of these ten years of partnership.

Felice Lembo – Chief Operations Officer Master Italy


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