Metal Ware Corporation Case Study

The Metal Ware Corporation, based in Two Rivers, Wisconsin, is a manufacturer of electric cooking appliances, including the NESCO® Roaster. The company was founded in 1920, and was purchased in 1931 by members of the family that still owns and manages the company today.

Over the years, Metal Ware has acquired a number of product lines and diversified into multiple business units: in addition to the manufacturing of cooking appliances, the company manufactures plastic components, and has a contract metal and tooling division that produces parts for other companies.

Metal Ware operated on a legacy AS/400 “green screen” system that had been in place for more than 25 years. They faced several challenges as a result: most significant was that it was tough for the management team to access the data they needed to run the business. Reports had to be edited and manipulated to present information effectively. Because of the difficulty of working with the system, Metal Ware was forced to rely on an outside consultant for their reporting needs and other changes.

Inventory tracking was also a problem. Plant shutdowns lasted for several days while inventory was counted and reconciled in the accounting system.

Schenck’s team of Sage consultants, led by Chuck Zuleger, assisted Metal Ware with the implementation of Sage 500 ERP including the fully integrated DCWarehouse wireless warehouse and shop floor automation system.

Today, inventory accuracy is near 100%. Parts can be pinpointed within the plant or warehouse, and shutdowns for inventory purposes no longer occur. “Schenck also assisted us with training our employees on the new software. The new system was a big change for us, but Chuck and Scott Firgens were there to help every step of the way,” said Tim Umphlett, who oversees Metal Ware’s IT.

Metal Ware’s management uses Crystal Reports for custom reporting, and can develop additional reports as needed. The company tracks and reports results for their plastics subsidiary separate from the parent company, and Sage 500 ERP enables them to much more easily do so.

“It was a pleasure to work with the Schenck Technology team on our Sage 500 ERP installation. They took the time to understand our needs, gave us their full attention and kept the project on track. It was a huge undertaking, but it went smoothly thanks to Chuck, Scott and their team,” said Don Kozlowski, Chief Operating Officer of Metal Ware.