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ERP CASE #030 - (CLICK/TAP TO EXPAND)
PARALLEL / FREELANCER:
WHERE:
INDUSTRY:
COMPANY:
ERP:
HOW LONG:
NOTES:
No / No
Italy
Packaging (Flexible Food & Beverage Film & Paper)
********** (Phase 1)
IBM AS/400 ACG (Applicazioni Contabili Gestionali) + Custom AS/400 "Sidecar" ERP
24 months
Hired twice directly by the CEO for distinct strategic initiatives, and later invited back a 3rd time. Sole decision-maker for all ICT, ERP, and Operational Technology (OT) initiatives.
ELEVATOR PITCH
Built IT and operational architecture from scratch over 24 months as IT Employee #1 reporting directly to the CEO.
Led the full rollout of IBM AS/400 ACG ERP while designing a custom sidecar module for complex film slitting, curing, and F&B lot traceability.
Led the Iimplementation of core IBM AS/400 ACG ERP from scratch, authored specifications for a custom AS/400 sidecar ERP for material conversion.
Overcame ERP limitations in complex slitting parameters, curing cycles, and F&B lot traceability.
Delivered an integrated IT/OT architecture covering 95% of plant operations.
Connected AS/400 directly to shop-floor PLCs, eliminating setup errors and drastically reducing scrap.
Tracked materials and yields via connected inline scales, barcodes, and RFID.
Integrated bi-directional AS/400 <<>> MS Project to automate production scheduling.
CASE DETAILS- (CLICK/TAP TO EXPAND)
Business Models
Make-to-Stock (MTS) / Make-to-Order (MTO)
Vacuum metallizing & coating of plastic film and paper for Food & Beverage packaging
Cut-to-Width (CTW) & Cut-to-Length (CTL) material conversion
Contract manufacturing / toll processing (lavorazione conto terzi) & direct sales
Areas / Modules / Domains
End-to-End Order-to-Cash (O2C): Order Inquiry to Shipping & Delivery Billing (~95% of total ERP process)
What (Project Scope & Deliverables)
Ground-Zero IT & Core ERP Rollout: Hired as IT Employee #1; led the full implementation of IBM AS/400 ACG ERP, replacing Excel/Access tracking.
Custom Sidecar ERP Design: Authored technical specifications for an AS/400 extension managing CTW/CTL slitting matrixes, curing/aging cycles, and F&B lot traceability.
SQL Data Extraction & Reporting: Leveraged SQL routines against AS/400 DB2 tables for rapid production reporting, yield tracking, material conversion audits, and operational troubleshooting.
Operations & Scheduling: Managed plant logistics and scheduling, bi-directionally integrating MS Project with AS/400 via CL procedures.
OT & SCADA Automation: Connected the sidecar ERP directly to metallizer Programmable Logic Controller / Supervisory Control and Data Acquisition (PLC/SCADA) systems to push recipes directly to CNC controllers.
Yield & Waste Control: Embedded automated inline industrial scales along production lines to monitor real-time yield loss and reduce scrap.
Auto-ID & Logistics: Implemented barcodes, shop-floor terminals, and early Radio-Frequency Identification (RFID) for finished goods intake and shipping.
How (Tech Stack & Implementation)
IBM AS/400 & ACG ERP
Custom RPG/AS400 Sidecar ERP Module & CL scripting (QSECOFR / QSYSOPR / QSYS)
SQL for DB2 reporting and rapid material yield data extraction
SCADA / PLC integrations & MS Project bi-directional sync
Inline industrial scales, Barcodes, and RFID
«It is NOT important WHAT you do,
its is important HOW you do it!»
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