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gallons of paint sold - enough to cover 6,000 square miles!
Paint manufacturer Dunn-Edwards Corporation had nine months to open its newest plant. Not only did plant operations need to integrate with the business, but the user interface had to be easy and provide real-time data.
Los Angeles, California, USA
SEAL Consulting Inc.
R&D, Engineering, Manufacturing
SAP Manufacturing Integration and Intelligence (SAP MII)
For over 80 years Dunn-Edwards Corporation has been the leading manufacturer and supplier of architectural and industrial coatings in the southwestern United States. Owned by its 2,000 employees, the company is famous for its superior quality paint and customer service. Dunn-Edwards has also consistently stayed ahead of the curve when it comes to protecting the environment, including eliminating lead and mercury from its products in the 1950’s and 1970’s, long before environmental regulations forced other companies to do so. Now, with a new environmentally friendly plant, that tradition continues, adding new layers to Dunn-Edwards paint and coating innovations.
72% of professionals polled prefer Dunn-Edwards
Dunn-Edwards paints are manufactured exclusively in the Southwestern United States and distributed and sold through approximately 110 stores in the states of California, Arizona, Nevada, New Mexico, and Texas. Landmarks from the Staples Center to Caesar’s Palace to Arizona State University are painted with Dunn-Edwards.
Committed to offering quality products, outstanding customer service, and industry expertise, Dunn-Edwards brings both color and know-how to every project to help make sure the job is done right.
Dunn-Edwards is a wholly employee-owned midmarket company of 2,000 people, and is one of the largest independent manufacturers and distributors of architectural paints and painting supplies in the United States. The Dunn-Edwards’ vision is to be the best and the greenest at what it does. With that goal in mind, the company made the bold decision to invest in a new manufacturing plant – an impressive 336,000 square-foot space that has been awarded the coveted Leadership in Energy and Environmental Design (LEED) Gold Certification for the design, construction, and operation of high-performance green buildings.
With multiple production lines that could produce up to 12,000 gallons of paint in just two to four hours, the new plant will play a major role in the Dunn-Edwards bottom line.
- Karl Altergott, President, Dunn-Edwards Corporation
Time to produce a single batch of paint: 3-4 people and 6-8 hours
It had been 45 years since Dunn-Edwards build its last plant and it was beginning to encounter constraints in production capacity. Processes were delayed, and it was hard to establish deadlines in the supply chain. Once it decided to build a new plant, it had just nine months to get it up and running. Not only did equipment need to be installed, it also had to link the shop floor with its business software and provide an interface that was easy for everyone to use.
Dunn-Edwards was already using the SAP ERP application as its enterprise solution, and the SAP MII would provide the support the company needed for the plant systems and machine interfaces for the operators. It would also work well with the business software. Dunn-Edwards wanted the business and the plant to “talk to one another” so it could operate more effectively. This meant it had to link business functions like production planning and order fulfillment with plant control systems and production equipment.
2x-3x Faster Rollout thanks to preconfigured templates
Dunn-Edwards needed to quickly integrate its existing SAP ERP application with the plant manufacturing system. Multiple IT and manufacturing engineering teams were involved and the rollout needed to be synchronized with the installation of equipment and control systems. Preconfigured templates were a huge time saver and played a major role in making the go-live date on time. Dunn-Edwards also had assistance from implementation partner SEAL Consulting Inc., which had previous experience with SAP MII and helped keep the process flexible and cost-effective.
Dunn-Edwards feels that the integrated SAP software landscape can help it better understand its customers. This is due in part to the introduction of the SAP CRM application. Deeper insight into customer activity allows the company to manufacture products accordingly as orders flow from the business software to SAP MII.
“I have been very impressed with the innovation coming out of SAP. We are very interested in mobile and analytics applications. We’re looking forward to seeing more details about SAP solutions in these two areas.”
With the new plant, Dunn-Edwards in now in a position to continue expansion. With the current focus having been on stores, the company is looking to developing international dealerships and products for home improvement stores. The next step for Dunn-Edwards will be to enter the world of mobile analytics, which will allow it to attract more customers while bringing customer insight and service to the next level.