Komali Tortillas Improves Inventory Control by 70%

"Our overall efficiency has significantly improved. Katana is a very user-friendly and easy-to-use system for each of the struggles that we used to have before. Even more, I appreciate the communication when they are developing new tools, they are open to feedback and take our improvements into account."
— Rafael Ysosa, Komali Tortillas
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Komali Tortillas Case Study by Katana
Komali Tortillas Logo
COMPANY:
Komali Tortillas
LOCATION:
Germany
EMPLOYEES:
"We tried other software as well. However, only Katana could provide visual insight into the production process. Overall user experience played a big role in this choice as well. The staff was helpful with implementation, and we seem to have made the right choice."
— Rafael Ysosa
Owner at Komali Tortillas

Company Profile

Komali Tortillas is a tortilla factory based in Hamburg, Germany. Komali Tortillas was born from the desire to bring authentic Mexican tortillas to all tables in European homes and restaurants. Their tortillas are made from 100% Mexican corn. Komali Tortilla products are made in Germany and can be purchased in such European countries as Norway, Sweden, Netherlands, France, Spain, Finland, and others. Komali Tortillas honors the traditional Mexican recipes and guarantees complete satisfaction to their customers - regular consumers and restaurants alike. Their tortillas do not contain animal products, are gluten-free, and are made with non-GMO Mexican corn to cater to various diets and health requirements. Apart from tortillas, one can order also a taco kit, various salsas and dips, and, of course, some Mexican tequila.
Katana case study of Komali Tortillas

Challenges

As a food producer, Komali Tortilla management quickly identified that the food manufacturing operations are complex not only from a production scheduling perspective where they need to manage product recipes, inventory, and operations. A big factor is also perishable inventory and compliance with food-safety requirements. At some point, spreadsheets did not cut it anymore and Komali Tortillas set out to improve their processes by:
  1. Adding full-traceability and expiry date tracking to their materials and finished goods;
  2. Tracking incoming materials and finished goods in their inventory; and
  3. Being able to see and plan production operations and improve task scheduling.

Why Katana?

We often hear that our customers come over from spreadsheets mainly due to all the moving parts that they are no longer able to manage manually. Komali Tortillas are one of them, and they also tried other software before choosing Katana.

We tried other software as well. However, only Katana could provide visual insight into the production process. Overall user experience played a big role in this choice as well. The staff was helpful with implementation, and we seem to have made the right choice.
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How Katana Helped

Now Katana has replaced the laborious spreadsheets and Komali Tortillas can direct their efforts to keep bringing high-quality tortillas to tables all over Europe. Furthermore, the end-to-end traceability function has allowed them to track expiry dates of raw ingredients and ready goods, as well as trace each batch back to the supplier. Overall, they have achieved the main goals they set out to solve:
  • Implemented batch tracking to meet the safety standards and reduce their risks;
  • Increased their production efficiency by more than 100% due to real-time master scheduling; and
  • Improved their inventory control by almost 80%.

As a consequence of improved production planning and inventory control, also floor-level operation management and on-time delivery have improved. “Our overall efficiency has significantly improved. Katana is a very user-friendly and easy-to-use system for each of the struggles that we used to have before. Even more, I appreciate the communication when they are developing new tools, they are open to feedback and take our improvements into account.”

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