Refactoring and customization of an ERP system for new operational workflows: the past, present, and future of aluminum

Intals: an overview

Intals S.p.A., a global leader in aluminum alloy production, delivers 140,000 and 60,000 tons annually from its two production sites. Acclaimed for its innovation and commitment to environmental sustainability, the company is accredited by certifications under international standards such as ISO 9001, ISO 14001, OHSAS 18001, and ISO 50001. This being said, it has experienced increasing operational complexity triggered by their international growth and shifting market demands.

When Intals reached out to us at Sensei, their primary management system was still built on COBOL technology.

The areas of concern

Their approach showed significant limitations:

• Outdated technology: the outdated COBOL system could no longer handle the growing operational complexities or support international expansion, making it difficult to integrate modern technologies and meet environmental and safety regulations.
• Operational vulnerability: the entire system relied on a single individual, exposing the company to operational risks.
• Increasing complexity: growth and new regulations demanded a flexible and up-to-date management system.

To address these challenges, Intals partnered with us to restyle their entire management infrastructure while ensuring the consistency of daily operations.

Our Solution: a step-by-step modular approach

To tackle the challenges associated with the COBOL system, we implemented a phased, modular plan for the redesign. Rather than opting for a full-scale, high-risk migration, we rolled out the iWeb system in stages, enabling users to transition smoothly and adapt gradually to the new platform.

During the transition, COBOL was kept operational, supported by a system that ensured synchronized coexistence and automatic data updates across both platforms. This approach facilitated a risk-free migration, minimizing disruptions while delivering a modern, adaptable solution designed to evolve with Intals' needs.

Implemented technical solutions

In 2016, we launched the project leveraging advanced technologies to provide flexibility, scalability, and flowless integration with Intals’ running system as follow:

• Frontend layer: built with JavaScript and dynamic libraries, offering an intuitive and responsive user interface.
• Backend layer: developed using .NET framework and SQL Server, providing a robust foundation for data management and business logic.
• Transition to COBOL: implemented synchronization via ODBC and custom C# libraries, enabling uninterrupted coexistence of the two systems.
• Mobile App: developed with Flutter, the app allows real-time warehouse management and logistics updates, allowing operators to work on the go.

The system’s flexibility enabled the software to adapt to Intals’ growing needs, accommodating both new functionalities and operational changes at the same time. Our approach prioritized scalability, ensuring that iWeb could also support the company’s future growth as integration with existing systems and new technologies was the core of our strategy ensuring fluid interaction between modules while enhancing information management and data processing.

Investigation, Design and Execution

By collaborating closely with Intals, we mapped out critical processes and pinpointed areas for improvement aligned with shared success goals. This approach enabled us to customize the system to meet the company’s specific needs, ranging from supplier and customer management to quality traceability and warehouse operations.

The launch of iWeb brought in technologies that automated key operations while cutting downtime by 30%. Custom solutions included a Windows application to streamline data exchange between industrial machines and a mobile app to facilitate warehouse operations. The COBOL migration was meticulously handled, maintaining parallel operational workflows and ensuring flawless data synchronization.

After the system rollout, we have preserved ongoing support for Intals, delivering updates to accommodate legal or internal process adjustments, such as new tax regulations or workflow modifications, ensuring the platform to be competitive and responsive to evolving requirements.

Our contribution

Our approach achieved major enhancements in efficiency, productivity, and risk management as follow:

• Enhanced productivity: automated recurring tasks, allowing staff to focus on higher-value activities.
• Reduced operational risks: modern infrastructure eliminated reliance on a single individual, making the system more secure.
• Achieved flexibility and scalability: modular iWeb system supports site development and facility expansion, including new production sites.
• Improved integration: streamlined accounting and optimized information record-keeping.
• Technological advantage: advanced technologies improved Intals’ efficiency and ability to respond to market demands.

Conclusion: an ongoing partnership

The iWeb project is continuously evolving, revolutionizing Intals’ operational management and equipping it to meet the demands of technological advancements. Built with flexibility and scalability at its core, iWeb is designed to adapt and grow alongside the company’s future business requirements, ensuring uninterrupted operational efficiency.