PSL Datatrack makes DP Engineering tick

Bracknell-based PSL Datatrack, a flexible and modular production control system for sub-contract precision engineers, has been the ‘unwavering heartbeat’ of Redruth-based DP Engineering for nearly two decades. Phillip Anthony, sales and marketing director at DP Engineering, said: “The software has revolutionised the company’s operations and driven its ongoing success.”

Established in 1952, DP Engineering has steadily grown, and now has 28 CNC machine tools and 36 members of staff. The business is often referred to as ‘Cornwall’s best-kept engineering secret’, specialising in the production of precision-engineered components with a particular focus on the aerospace and oil and gas industries.

Before adopting PSL Datatrack in 2005, DP Engineering relied on manual administration and Excel spreadsheets to manage its operations. While these manual processes were functional, they had limitations that hindered efficiency and scalability. As the company grew, it became clear that a more robust solution was necessary to support its expanding customer base and complex production requirements. PSL Datatrack emerged as the ideal software package to meet these demands head-on.

Mr Anthony said: “PSL Datatrack is the driving force behind our company. It helps us to identify profitable jobs with the ‘Job Costing’ module and ensures that everything runs seamlessly from quotation and contract review to delivery and invoice.”

Meanwhile, PSL Datatrack’s ‘Quotations’ module has been used from day one. Geoff Gartland, managing director of PSL Datatrack, explained: “Getting the quotation right is the starting point. Having the correct set-up means there are no mysteries from the point an order is processed, ensuring a smooth flow throughout the rest of the PSL Datatrack system.”

Furthermore, material tracking, sub-contract processes, works orders, purchasing, stock control, scheduling, shopfloor data collection, gauge calibration, non-conformance, contract review and tooling requirements, are just some of the many system features DP Engineering has invested in.

Numerous benefits
Use of PSL Datatrack has yielded numerous benefits for DP Engineering over the years. Template quotations are available for similar components, allowing estimates to be created in minutes. This feature has significantly reduced the time spent on administrative tasks.

All modules are seamlessly linked, ensuring that the retrieval of information is easy and efficient. This integration means that all staff members can quickly access the data they require without any queries. For example, the ‘Material Stocks’ module has simplified the process of checking and maintaining material prices. Mr Anthony said: “Keeping track of material costs has never been easier. PSL Datatrack guarantees accurate and up-to-date pricing.”

Shopfloor data capture is crucial for accuracy and efficiency in modern manufacturing. By collecting real-time information from the shopfloor with PSL Datatrack, DP Engineering gains invaluable insights into every aspect of production, including quantities made and scrapped as well as overall performance in comparison to quoted time. The ‘Shop Floor Data Collection’ (SFDC) module has enabled the company to go paperless in some areas, eliminating clutter and the potential for errors associated with physical documentation. These benefits have resulted in reduced bottlenecks and increased production capacity, allowing the business to meet higher demands.

Alongside the introduction of new machines and automated technology — including gantries, bar feeders and pallet systems — PSL Datatrack has enhanced DP Engineering’s proactive approach. This combination of advanced software and cutting-edge machinery keeps it at the forefront of the industry.

DP Engineering also values the flexibility and customisation options provided by PSL Datatrack. There are over 1,600 configuration options within the system which can be individually set to the preferences of the company using it. These can be tweaked at any time to ensure that the system continues to fit like a glove and to suit changing requirements as the business continues to grow.

Configuration has also encompassed numerous custom reports for particular reporting requirements, along with powerful status boards to display live production data on the shopfloor. This means all employees know where a job is and what needs doing next. Mr Anthony remarked: “The standard reports included in PSL Datatrack’s Sequential Scheduler module are also crucial for maximising efficiency and machine shop output. They are like gold dust.”

Complete traceability
As an AS/EN9100 Series Aerospace and ISO9001:2015 accredited business, traceability is a critical requirement for DP Engineering. PSL Datatrack ensures complete traceability from the moment materials are received, through to the delivery of finished products to customers.

Mr Anthony explained: “When we ship an order, we have traceability throughout the entire production process. Each product has a Certificate of Conformity and a delivery note with traceability back to the material’s arrival and usage on the shopfloor. This not only streamlines our internal processes but also provides our customers with the assurance of quality and transparency, enhancing their confidence in our products.”

PSL Datatrack’s robust traceability features have made external audits much more straightforward. He continued: “A single report showing all the information related to a works order can be generated with a click, ready to show to the auditor in seconds.”

PSL Datatrack’s customer-focussed approach has fostered a strong working relationship with DP Engineering. The Wishlist system allows DP Engineering the option to suggest new features, and extensions to existing ones, many of which have been implemented by PSL Datatrack over the years. Mr Gartland commented: “Ideas from customers are gratefully received and the Wishlist system demonstrates our commitment to continuous improvement and customer satisfaction. It has been a rewarding experience working with DP Engineering.”

Looking to the future, DP Engineering plans to continue leveraging PSL Datatrack’s capabilities to retain and develop new business and drive further growth and innovation, including password-protected shopfloor transactions for even tighter traceability.

The company’s proactive use of the software for sales pipeline reporting, regular customer health checks, KPI dashboards and management overview information ensures it remains a leader in sub-contract precision engineering.