1. About KitPackers & ResinLab
KitPackers was founded in the early 1970s in Minneapolis, MN and then purchased by Ellsworth Adhesives in To further the efficiencies of the two companies, KitPackers was moved to Germantown, WI in 1987.
In 1994, KitPackers combined operations with Resinlab, another unit of Ellsworth Adhesives and moved into a new facility on Morse Drive in the Germantown Industrial Park. The new Morse Drive facility was built adjacent to the Ellsworth Adhesives facility on Fulton Drive. The three companies, KitPackers, Resinlab and Ellsworth Adhesives complimented each other tremendously:
KitPackers provided custom chemical packaging
Resinlab formulated and blended resins to customer specifications
Ellsworth Adhesives distributed these products together with a complete line of specialty chemicals from major manufacturers.
The result of this synergy was rapid growth that necessitated the need for more space for all three companies. In 2003, Ellsworth Adhesives moved to a new 85,000 sq. ft. World Headquarters and Distribution Center in a new Germantown business park. The move made the Fulton Drive facility available for KitPackers, and allowed KitPackers to quadruple its manufacturing space, purchase new state of the art packaging equipment, and improve overall efficiencies.
On December 14, 2012, KitPackers and Resinlab moved into this 107,000 square foot facility, just five miles from the Fulton Drive location and very near the main Ellsworth Adhesives building. The new building greatly expands production, laboratory and office space for the business with room to expand as the business grows.

2. What We Do
KitPackers® is a custom chemical packager of one component and two component resins such as adhesives, encapsulants, sealants, coatings, greases, lubricants, cleaners, primers and a wide variety of other industrial chemicals.
ResinLab® is a leading resin manufacturer with state of the art production equipment, lab capabilities, and technical expertise.

3. NAV Background Prior – Two Ellsworth entities implemented NAV 2009
2013 – KitPackers and ResinLab implemented NAV 2009
2015 – Ellsworth divisions on NAV upgraded to NAV 2013 R2
2016 – Ellsworth Corporation began consolidation in NAV
All global divisions reporting via NAV chart of accounts; disparate systems
2017 – Preparing for upgrade to NAV 2017
Current ISVs:
KwikTag: document retention
Jet Reports: report writing
Lanham: E-ship for FedEx and UPS
ChargeLogix: credit card processing
DocumentPath: sending documents to external parties
Production Scheduling (Planner One): Live last month
Future ISVs:
Warehouse Management (DMS): Bar-coding, project kicked off last month
Quoting Solution (Experlogix)
Labor Tracking (DMS)
EDI (True Commerce)

4. Please wear safety glasses
Building Tour
Please wear safety glasses

5. Sales Quote
Quoting department creates quotes and Routing/Bill of Materials
Sales quotes are used to communicate pricing to customers
Modification: Quote form
Pricing still resides in pricing table
Leveraging NAV
Standard Text Codes – standard language across quotes
Extended Text – from Item Card to Sales Quote
Supporting Documentation tied to NAV:
Link to Excel worksheet that outlines costing of product
KwikTag to tag all quote related documents (request, notes, SDS, vendor info)
Future ISV: Experlogix solution in the next six months

6. Customer Places an Order
Customer card created by customer service
Card is blocked until someone with ‘Accounting Permission’ finishes the setup and unblocks the card (user setup)
Customer documents attached to the card with a Links box
Comments with codes used to track various notes about the customer
We use document path – invoices, credits, and order confirmations set up on the customer card
Order is entered by customer service
Accounting may need to release orders on Credit Hold
Use KwikTag to tag and view customer’s Purchase Order from NAV
Production inserts comments on the line for status of manufacture
Pricing populates from price table
Bill to vs. Sell to – we have a lot of sell-to’s from 1 major bill-to
Modification used to handle tracking and payment of commissions – using rules like GP goals
Sale Return Orders
Goods returned are received on a SRO to location NON-CON and bin NON-CON
Use the function ‘Get Posted Document Lines to Reverse’
Use KwikTag to tag all related documents

7. Prepare for Production
All manufactured items have Routings and BOM’s
Standard costing – standard method of manufacture is on the item card
Modified NAV to create a BOM/Routing table – when this customer buys/use this routing, has quantity breaks, and has yield from column (specified for our business)
Fully utilize work centers – overhead rates
Routing link codes on Routing/BOM are used to ensure components print on job card under the correct work center
Below are a couple pages to a typical production order

8. Purchasing Standard NAV PO’s are created
Replenishment System: Purchase
We use Fixed Reorder Quantity with reorder quantity for stocked items
Everything else uses Lot for Lot (buy and consume)
Use planning worksheet filtered to Purchase to create purchase orders – with start/end dates
Replenishment System: Production Order
Resinlab production orders are created this way
Stocked Kitpackers manufactured items are created this way
Planning from the sales order
Purchasing creates most purchase orders for Kitpackers

9. Subcontracting Purchasing (continued)
Subcontracting Worksheet – work center is set up for a vendor.
Internal flows for inventory control pull all raw inventory
Stage in certain BIN
to purchasing
Purchasing creates PO and sends to vendor

10. Vendor Score Cards
We capture data to calculate a vendor score using Jet Reports – delivery, providing promise dates, and quality data

11. Purchase Quotes
Standard purchase codes are setup and attached to vendors. Employees can create a purchase quote and attach a standard purchase code. When the employee sends for approval, the system uses Document Approval / User Setup to work through and document the approval process

12. Product Realization Product Realization
We use standard NAV cycle counts with the Physical Inventory Journal (ABC codes on the SKU)
Staging raw materials for the Production Order
Modification to help create the reclass journal – to move from warehouse bin to a staged bin
We have Lot number traceability on all the chemicals – from receipt to consumption
Use Output journal to post labor by Employee. Also use the Capacity journal to post indirect labor. This information is used along with Jet Reports to create productivity cards by employee
We use Reservations to track where raw material and finished good inventory is used.

13. Delivery & Invoicing Shipping We use E-Ship for shipping FedEx & UPS
Other truck shipments: warehouse shipment with manual tracking input to NAV
Invoicing
Prior – Review of Order Entry Audit Jet report
RTC to accumulate all invoicing and cost review screens in one location
Including a Shipped Not Invoiced filtered list
Post Batch to invoice sales orders
Send Using Setup to send posted invoices via DocumentPath

14. Intercompany Accounting
IC Inbox / IC Outbox
Use Intercompany in/out boxes to transfer sales orders, sales invoices, purchase invoices and intercompany journal entries
Dimensions
INTERCO code
Split expenses
Department / Unit Code
Jet reporting
Sales
Variance analysis
Cash application

15. Quality
Use a modification to record quality results

16. Scheduling Software Scheduling Software
Recently purchased Planner One. Not fully implemented.