Custom software unlocks efficiency and value at Haines Finishing Co.

Challenge:

Outdated software and lack of real-time visibility created inefficiencies and delays at an industrial powder coating company.

Solution:

A unified custom software solution that supports their unique workflows and manufacturing processes, running on workstations in the office and iPads on the production line.

Results:

• Seamless data flow and end-to-end visibility reduces downtime and errors
• Significant cost savings due to less downtime, less paperwork, and fewer bottlenecks
• Deep customization supports their efficient business processes and positions them for future growth

“Skeleton Key did a great job. Their people are thinking outside the box. Working with them was an exciting time, and what we built together was amazing.”

 — Gina Haines, Director of Operations, Haines Finishing Co.

Haines Finishing Co. is a family-owned and -operated industrial powder coating company based in New Haven, Missouri. But don’t let that humble description fool you. Haines Finishing sports modern technology and regularly handles large jobs and high-volume runs. Their commitment to quality, customer service, and good communication for over three decades has earned them a reputation for excellence in the industry.

An average order for Haines Finishing consists of tens of thousands of parts to be powder coated — a specialized, high-temperature process that begins with careful preparation and cleaning before adding a durable, textured finish. The company also has a second production line specializing in rubber handles and coatings on metal parts, with its own workflow that also requires centralized management. In addition, Haines Finishing offers a range of value-added services including final assembly, labeling, and packaging.

The technology they use for powder coating is state-of-the-art, but Haines Finishing first called on our team when the technology that helped run their business was no longer up to the task.

Challenge: Outdated software for managing production

Years ago, Haines Finishing had adopted a popular relational database solution for processing and tracking orders, and for managing customers, customer parts, quotes, jobs, materials, vendors, and billing. At one time this software had been innovative, but now it was no longer receiving support or updates.

Without a new version available to purchase, the company tried to make the aging software work while they searched for an alternative. But this led to drawbacks for operational staff. The database software could be used only on a single, older computer in the office, resulting in bottlenecks. Meanwhile, their financial software vendor dropped support for the version of the operating system that ran on this older machine, leading to additional compatibility issues.

These combined challenges meant that, on any given day, the company was dealing with a slow program on a slow computer that only one person could use at a time — not to mention the occasional software outage that would require hours of third-party technical support to fix.

Further complicating matters, production processes on the factory floor were documented on paper. When customers asked for updates on jobs, an office worker would have to find that information on the production line, often digging through paperwork or interrupting jobs in progress to do so. Meanwhile, those papers had to be kept on file when jobs were done, taking up a large amount of office space.

Leadership wanted to solve both issues — outdated software and an inefficient, paper-based production process — by supplying line workers with iPads. But they lacked a way to integrate the new technology with their existing hardware and legacy database software. While an off-the-shelf MRP software package might have been able to solve these challenges, it would have been costly to implement and would have required compromises in how their team worked.

Haines Finishing’s leaders knew they needed a custom software solution that would integrate jobs, vendors, materials, and billing — one that would address their immediate needs and support anticipated future growth, all while giving them the level of control they needed.

Their staff were tech-savvy and knew how this ideal software should function. What they needed was a partner to help them execute their vision.

Solution: Versatile custom software and end-to-end transformation

Haines Finishing evaluated several vendors, but ultimately selected Skeleton Key for our depth of experience in custom software development — in particular, our ability to build a scalable, reliable solution to their specifications on the proven Claris FileMaker platform.

But more than that, Haines Finishing chose Skeleton Key because of our willingness to work collaboratively with them. “I wanted to find a company that shared my vision and that was willing to work with us to achieve what we wanted to do,” said Gina Haines, director of operations. “And Skeleton Key’s team was willing to work with me, not over the top of me.”

This collaborative, consultative approach to software development meant that minimal tuning was required after deployment — a process that would have taken months or years to accomplish with off-the-shelf software, and that would likely be impossible to achieve with a SaaS solution.

Once we understood their processes and needs, as well as their long-term goals, our team coded a unified software solution for modern workstations in the front office and iPads on the production line. This creates a seamless flow of real-time data throughout the company.

Results: Reliability, efficiency, & real-time visibility at a much lower cost

The result was as transformative as Gina and her team had hoped. Right away, there were no more bottlenecks or work stoppages due to outdated or unsupported software.

Now that line workers had iPads, office workers had access to real-time information and could answer customer questions without leaving their desks. Today, this increased visibility allows team members to proactively avoid production errors.

The custom software we built is flexible enough that they went on to manage their rubber-coating production process through the same interface.

Haines Finishing’s investment in custom software and iPads has generated significant new revenue and cost savings in the years since initial deployment:

• Increased gross profit by $200,000 per year without the need for additional hiring
• $6,000 per year saved by freeing personnel time to focus on customer service and quality
• Reduced downtime on production lines resulted in $50,000 per year in increased revenue

Today, Gina said, team leads spend more time focusing on quality and job efficiency rather than paperwork, which improves job satisfaction and employee retention. And, since they no longer have to store so many paper records, they’ve reduced their carbon footprint and reclaimed office space.

“Skeleton Key did a great job. Their people are thinking outside the box. Working with them was an exciting time, and what we built together was amazing,” Gina said.

What’s more, Gina said, her clients noticed the difference. She said customers have been impressed by Haines Finishing’s adoption of technology, especially the team’s ability to give quick, accurate job status updates. All of this has helped them maintain their longstanding reputation for quality and excellence.

Custom software built by a partner that shares your vision

Today, Haines Finishing remains a Skeleton Key client because they know we’re willing and able to work collaboratively with them.

“If we come across something we want to add, something we want to do in the future, all I’ve got to do is pick up the phone,” Gina Haines said. “That’s the kind of relationship we have with them.”

No matter how technologically sophisticated your team members may be, Skeleton Key is ready to meet you where you are and help you achieve your vision. We start by understanding your needs and your long-term goals, then work with you to build a solution that fits your needs perfectly.

Book a consultation with us today and find out how we can help you operate more efficiently and securely with custom software.