Molda AG
Molda AG

MOLDA, a leading specialist for desiccating high-value foodstuffs, has worked successfully with ORDATs ERP-System FOSS since 1999

The MOLDA AG located in lower Saxony

has an excellent reputation in the food-processing sector. For more than a century, in the year 1892, as the dairy processing board Dahlenburg was founded, MOLDA was already specialized for more than 50 years in the desiccation of foodstuffs. Nutrient supplements, bakery/ catering mixes as well as the commissioned dehydration for an international clientele belong to the products and services of the MOLDA AG. In 2004 the 430 employees of MOLDA earned a turnover of more than 75 Mio. Euro. Four different, modern desiccation technologies at one site  – a globally unique offer – guarantee MOLDA customers the highest degree of flexibility. Therefore, for each product the optimal desiccation conditions can be provided.

Special requirements for the computer technology that is applied, which must run continuously and trouble-free around the clock for 365 days of the year, result from high quality standards. This does not only apply for the scanner technique, with which the complete production is executed at MOLDA – because temperatures down to minus 50°C prevail in MOLDAs cold-storage rooms – ten of the total of 40 scanners that are used are especially designed for extremely cold conditions. The drying of foodstuffs, with their extreme alterations of weights between input and output products, as well as the recipe-orientated manufacture, together with joint-production, also require above all a flexible and efficient operations management.

The Proper System

In 1998 the management of MOLDA decided to replace the Comet group-constrained solution (which had been used until then to control the business process, but which no longer offered any possibility for further development) with a ERP Standard Software that would provide more security for the future. The ERP-System FOSS from ORDAT was chosen relatively promptly: The performance scope of FOSS, especially the strengths of the system for process manufacturing, convinced MOLDA as well as the excellent references of the Gießen software establishment in the food-processing industry.



High Demands

The main objective of the introduction of FOSS was the procurement of a uniform logistical system that extended over all domains of the corporation. Thereby, the main emphasis was placed on customer satisfaction, especially on dependable quality assurance and safeguarding a high readiness to deliver. A further important requirement was the planned incorporation of future subsidiaries. In Dahlenburg, MOLDA implemented FOSS with the part systems purchasing, sales, production, warehouse management, FOSS-EDI and FOSS-Mobile. On the basis of their mature functionality for the food-processing industry and process manufacturing, for example the well-developed lot monitoring and efficient warehouse management, FOSS already met nearly all of MOLDAs requirements in the standard version.

Therefore, merely a few company-specific adaptations were necessary, mostly in the module „warehouse administrative system LVS“. The warehouse management at MOLDA occurs dependent on lots, warehouse sites and QA statuses. MOLDAs products are fundamentally lot-obligatory.

FOSS offers hereto an efficient lot monitoring: For example, in the event of a complaint, the pertinent intermediate products and their suppliers can be identified and effective lots will be appropriately indicated. In order to ensure optimal product quality, various statuses were defined by MOLDA, which indicate the quality and utilization of the stored foods; if the goods can be sold (quality „very good“), should they only be made available for mixing with other lots, must they still be verified or do any impairments exist? An inventory evaluation that can be configured in dialog offers a rapid overview over the inventories and enables a lot-based registration as well as massive modifications of QA statuses. Therefore, it is possible to block entire lots by pressing as button, as needed.
 

Joint Production and Recipes are already in the Standard

Upon dehydration that begins with an initial material, powder is often created with different strengths of granulates. In such instances, several final products exist for a single production order (joint production). In the recipes, flexible mass relationships must be managed from the initial material that is still not dehydrated to their respective final products (wet-dry-recipes). FOSS also supports this functionality already in the standard – for MOLDA existing percent numbers merely had to be expanded.

Drumbeat

For the introduction of FOSS a special challenge arose: Exactly 6 months after the decision to introduce the system, on April 1, 1999, a so-called „Big Bang“ was supposed to occur as a complete introduction of all part systems. This was no problem for the three-man ORDAT team and the contributing colleagues from MOLDA. The parallel work in purchasing, sales, production and warehouse management made an efficient performance possible.

„We were very satisfied with the course of the project and the quality of the results“, said the IT-Leader Heine. „Also, very special requirements were implemented rapidly and efficiently – the ORDAT consultants understood us very well.“

In Dahlenburg 48 users are working at present with FOSS, who were very thoroughly trained by ORDAT. Furthermore, regular training sessions and application instructions are given, in order to keep the users up-to-date about new functions.
In 2003, MOLDA also implemented FOSS-Mobile, ORDATs application for a wireless data registration in delivery and warehouse. With the aid of Barcode-Scanners with online access to the central ERP-Server, FOSS-Mobile permits an efficient booking of goods in issue and in receipt and the collation of target and actual inventories on site. In addition, the ORDAT consultants supported MOLDA with the link-up of FOSS to an external QA system.
In the near future, a link-up of two subsidiaries (MOLDA France in Rennes, and Húngaria Kft. in Pilisszentiván, Hungary) will be made to the ERP-System that is located in Dahlenburg. Thereto, MOLDA has purchased FOSS licenses in the language versions English, French and Hungarian.

„The conversion to FOSS was worthwhile“, recapitulated Joanna Heine. „We now have a system that is secure for the future, which will also expand commensurate with our increasing demands for the future.“

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