To keep up with the ever more demanding requirements of its customers, Northamptonshire pie and pastry manufacturer Saxby Brothers has entered its second century with support from a TROPOS ERP solution from SSI.

Saxby’s was established in 1904 by two brothers and it is still a family concern. Herbert and Ted Saxby opened their first pork butchers shop in Wellingborough, and produced their own recipe pork pies and sausages. Their business quickly expanded, and they moved their production to the present site in 1924.

The company has achieved many major goals and landmark successes since those early days. In recent years, the site has expanded and developed many times. Saxby’s is committed to future growth of the business, and is constantly on the lookout for expansion opportunities.

Major investments in development

In the past decade alone, over £10 million has been invested back into the business. Most recently, a £500,000 purpose-built development centre was opened with state-of-the-art kitchen and presentation suites where customers can work alongside the company's development chefs to create new products.

Today, alongside the Saxby family, some 400 people are employed, many of who have worked for the company for over 20 years.

Saxby’s is famous for producing many products including Melton Mowbray pork pies, ready to use pastry products and high quality pies, all of which can be found on the deli and in chilled sections of many food stores. The company also produces bespoke, own-label pastry-based meat and vegetable products for UK supermarkets and foodservice outlets.

It sells directly to the major retail outlets and foodservice operations, and supplies many smaller retailers and foodservice outlets through a nationwide network of distributors. Its turnover of more than £18 million is mostly from fresh and frozen products that are meat and pastry based.

Most of its products are manufactured on a “day one for day two” basis – orders are received on the first day, for overnight despatch into the customer’s depot on the following day. This ensures that products arrive fresh on supermarket shelves – and that their shelf life is as long as possible.

In practice, this means that orders are received up to 3pm each day and they have to be despatched by 10pm. On top of that, Saxby’s must meet delivery windows of just one of two hours – and retailers are increasing the pressure on manufacturers by bringing delivery times further forward.

Forecasting is a key ingredient

Forecasting and production planning are vital ingredients of the Saxby’s business model, enabling it to keep pace with its customers’ requirements. For this reason, Saxby’s decided that its obsolete systems had to be replaced. It selected TROPOS and Coda Financials from SSI.

Managing director Bill Saxby says the introduction of TROPOS provides the foundation for achieving new business objectives. These include improving customer service and reducing the number of “not availables” – shortfalls between the customer’s order and the products despatched.

Saxby’s initially rolled out sales order processing, purchasing and financial modules. It subsequently implemented modules to cover its production activities. The integrated TROPOS system has given the company a firm base for efficient manufacturing – reinforcing Saxby’s mission of high quality products made under conditions of excellent manufacturing practice.

Bill Saxby says: “The system is fundamental to acting on orders in the speediest and most timely fashion.”

More effective response to customers

The Customer Services department ensures that all orders are processed on a daily basis, with constant liaison through the forecasting team, planning team, production team and finally to the despatch team. As orders are received, they are entered on to the system so that the company’s planners can monitor progress against the production plan and the master schedule. Other staff are also able to act as soon as information comes into the company. This allows them to respond to customer requirements more effectively – generating pick notes for despatch immediately an order is received by EDI, for example.