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Learn how Global Fire Equipment gained real‑time visibility, ERP‑connected production control, and better traceability using Fusion Operations.
Fusion Operations: Manufacturing Insights at Your Fingertips
Fusion Operations provides real-time data to optimize scheduling, inventory, and quality.
Manufacturing fire detection and emergency systems demand precision, visibility, and control. Now part of Global Safety Systems (GSS) Group alongside two other companies and operating under world-leading fire and safety organization Ampac, Global Fire Equipment’s growth brought another level of production complexity.
Any number of the combined 100+ products, multiple production styles, and vastly different manufacturing volumes flow through the single factory every day. Before their acquisition, Global Fire Equipment started a new implementation with Fusion Operations and integration with their ERP. It had become clear that production management needed to change.
“We were producing in a very chaotic way,” says Fernando Oliveira, General Manager, GSS Group. “At the time, the company was looking only at cost-effectiveness and not timing or process. The move to Fusion Operations has transformed the business from where we were and where we are now.”
Adopting Fusion Operations for the shop floor and integration with ERP
Based in São Brás de Alportel, Portugal, Global Fire Equipment and GSS Group provide a wide range of safety products, including fire detection panels, smoke and heat detectors, alarm devices, emergency lighting systems, and much more. Production volumes vary dramatically, anywhere from a product built once a year in batches of five to another they manufacture up to 5,000 units per day. With the move to Fusion Operations and then integrating it with their ERP using the Fusion Operations API, they gained new insights and improved productivity.
Before the transition to Fusion Operations, Global Fire Equipment faced a host of challenges. Too much material was often consumed at the start of a production order, and they never knew just how much stock was actually on hand at any given time. Now they can identify exactly where and how materials are being used and target issues right away.
There was also a limited view of how time was spent on the shop floor. For the first time, the company gained clear insight into how long individual tasks took and where inefficiencies were hiding.
“Things are much, much better with Fusion Operations,” Oliveira says. “The main highlight for me is the visibility to understand how much time we are spending on each task in assembly and adjust it for greater efficiency.”
“Teams are easily adopting it and gaining insights they wouldn’t have previously,” he adds. “For example, the purchasing department has more information about what is being consumed in production so we can better prepare.”
Finding new success with traceability
Traceability is essential. But implementing it across such varied production scenarios can be challenging. Global Fire Equipment’s high-volume products can rely on lot tracking, while the more complex products require serial numbers tied to multiple subassemblies and components.
With Fusion Operations, they are making new inroads. While the company is still expanding its use of serial-level traceability, lot-based tracking is already producing great results.
“We’re looking forward to adding new levels of traceability using Fusion Operations,” Oliveira says.
“Fusion Operations is one of the easiest tools to implement and use on the shop floor. There are a lot of features to manage purchasing and traceability. For me, Fusion Operations is a very positive experience.”
– Fernando Oliveira, General Manager, GSS Group
A journey worth taking with Fusion Operations
The transition to Fusion Operations did take some time, but the outcome has reshaped Global Fire Equipment’s manufacturing process.
“Many things have improved for us by using Fusion Operations,” Oliveira says. “Now we can really see and take action with the number of wrong products, amount of rework needed, or number of damaged pieces. We can address all of it with Fusion Operations.”
Looking ahead, Oliveira sees even greater potential as processes continue to mature.
“I’ll just say, I’m happy,” he says. “I’m looking forward to even more from Fusion Operations, and I see a huge potential for growing and improving to a much bigger level.”