When TAPCO, a leader in traffic and pedestrian safety solutions, decided to invest in a Manufacturing Execution System (MES), they weren’t just looking for another piece of software. They wanted a game-changer for their shop floor operations.
Their goal was clear:
- Empower every operator to manage production orders easily.
- Eliminate process bottlenecks.
- Gain real-time visibility into performance.
The solution they chose, MV2 MES integrated with Microsoft Dynamics 365 Business Central (BC), delivered exactly that, and more.
We sat down with Troy Eggers, Manufacturing Manager at TAPCO, to learn about their journey implementing MV2 MES and the transformation they’ve experienced since going live.
Inside TAPCO’s Manufacturing Operations
TAPCO’s production environment is far from one-dimensional. They operate as a hybrid of manufacturing models:
- Engineer-to-Order (ETO) for custom safety solutions.
- Make-to-Order (MTO) for project-specific builds.
- Stock Manufacturing for high-volume, ready-to-ship items.
As Troy explains, “We’re part job shop, part mass production. We produce products for roads, streets, and sidewalks, from traffic signs to pedestrian safety systems. That mix means we need flexible tools that work in all scenarios.”
The Pre-MV2 Challenge: A One-Person Bottleneck
Before MV2 MES, TAPCO’s process for closing released production orders (RPOs) in BC was limited to one person with the technical knowledge to navigate BC’s interface.
This created several challenges:
- Centralized dependency – All RPOs had to go through a single point of contact.
- Inventory delays – Parts would pile up in queues all day until they were finally posted in BC at once.
- Material handling crunch – The end-of-day “inventory flood” overwhelmed the material handling team.
“We needed something that made it simple, touch of a button, done,” Troy says. “Our main goal was to spread that capability across the floor so everyone could do it. That way, no one was waiting on one person to keep production moving.”
Choosing MV2 MES: Data Access and Flexibility
When evaluating MES solutions, TAPCO prioritized access to data and reporting flexibility. MV2 MES stood out for several reasons:
- Complete Back-End Access – Their team could tap directly into data and build custom reports tailored to TAPCO’s needs.
- Pre-Built Reports – MV2 came with useful dashboards right out of the box.
- Local Partnership – With ISE’s proximity, collaboration and support were easy.
- Opportunity to Pioneer – TAPCO became the first BC customer to implement MV2 MES, shaping its development for other manufacturers.
“Other MES systems we looked at didn’t give us the same level of data access,” Troy explains. “With MV2, we could control and customize our reporting. That was a big selling point.”
Onboarding and Early Adoption
TAPCO was very satisfied when onboarding went faster than expected.
- Training Duration – Two days of training were planned, but Troy believes they didn’t even need the full time.
- User Friendliness – The interface’s big buttons and simple workflows meant operators could start using it immediately.
- Quick Rollout – Within a week, MV2 MES was fully in use on the shop floor.
As with any new system, there was initial skepticism. “At first, people thought it would slow them down. They worried about extra steps,” Troy recalls. “But once they saw it didn’t hurt productivity, and made their jobs easier, the pushback disappeared.”
MV2 quickly became part of TAPCO’s culture. When a new work cell launched without MV2, operators complained. “That’s how I knew it worked; they didn’t want to be without it.”
Tangible Improvements Since Go-Live
TAPCO’s MES transformation is backed by measurable results:
1. Continuous Inventory Flow
Before MV2, material handlers waited until the end of the day to receive all posted items at once. Now, operators post as they go, keeping work moving and eliminating the daily backlog.
2. Improved Material Handling Efficiency
By spreading inventory posting throughout the day, material handling teams can keep pace without late-day surges.
3. Real-Time Performance Visibility
Large dashboard displays on the shop floor show production cell status in green, yellow, or red. Supervisors know instantly when a cell is behind and can address issues in real time.
4. Root Cause Analysis for Process Issues
When a cell falls behind, MV2 makes it easy to investigate whether it’s a staffing issue, equipment problem, or process bottleneck. Operators can provide direct feedback, helping leadership pinpoint improvements.
5. Operator Empowerment
With MV2’s simple interface, operators no longer need BC’s technical training. Instead of navigating multiple BC screens, they just press four big buttons, fast, intuitive, and error-free.
A System Built for Growth
Troy points out that BC was designed with add-ons in mind — and MV2 takes full advantage of that capability.
“BC is very technical for the average user,” he says. “MV2 gives you a much simpler, better-looking interface that’s easier to interact with. Instead of a map of steps in BC, you’ve got four buttons and you’re done.”
Advice for Other BC Manufacturers
When asked what advice he’d give to other BC manufacturers, Troy’s message is clear:
“If you want your team to use the system and see value from it, go with an add-on like MV2. It’s faster to learn, easier to use, and integrates perfectly with BC.”
The Bottom Line
TAPCO’s implementation of MV2 MES didn’t just solve their original bottleneck problem; it reshaped how their shop floor operates. By giving operators direct control over posting, enabling continuous flow, and providing real-time visibility, MV2 has become a daily essential.
And for TAPCO, being the first BC customer to use MV2 wasn’t a risk; it was an opportunity to innovate.
Ready to see how MV2’s user-centric design complements your machine data and transforms your shop floor? Your operator and your production metrics will thank you for making the switch. Contact our implementation team to schedule a demo and see how MV2 can transform your shop floor. You can also contact ISE at info@ise-erp.com or 262-567-9240.