One of Corona Covid 19 lesson is that the effectivity in production matters more than ever. High production efficiency can prepare you to stand next corona well.
All the information you need to increase your productivity and hit your targets already exists. You just can't see it.
If you saw all this information in real-time, you would be able to make decisions that increase productivity and avoid unnecessary downtimes.
or scroll below to read the case study
We know our product may seem complicated and abstract. For a non-IT person, it’s often hard to imagine how software can eliminate downtimes and raise production efficiency. Let us show you a real-world example from one of our clients.
A German-based global leader in heating, cooling and hot water products and solutions with 13,000 employees around the world and an annual turnover of EUR 2.5 billion. The group has 10 production and development sites in 6 European countries (Germany, France, UK, Spain, Slovakia, Turkey) and the People’s Republic of China.
The client had a problem with unscheduled downtimes caused by ineffective material line feeding process on the production line. This was causing missed targets, lowered production efficiency and poor KPIs like OEE. They decided to face this issue. The entry analysis revealed several issues.
No overview No overview or control over the line feeding process caused delays in information flow. That limited improvement possibilities in real-time.
Missing data Missing data often caused material shortage on the line, extra inventories or wrong material deliveries. This caused production delays and more downtimes.
On-demand deliveries Line feeders were feeding the line with the material on a random basis or with fixed time slots. Often doing round trips with half empty vehicle trains. Unscheduled downtimes due to missing, delayed or wrong material were happening on a regular basis.
Long changeovers Also, with this setup, it was difficult to support many product variants with different BOMs exchanging rapidly causing excessive changeover periods prolonged downtimes even further.
Bottom line Logistics of material flow to and from the production was random and ineffective.
After analyzing the core problem we created a custom software solution – a smart electronic Milkrun. The main improvement was the digitalization of the whole production which enabled data collection and reactions in real-time. The new Milkrun solved all the issues.
Full control The leaders and management have full control and monitoring capabilities over the line feeding process with an early alert system.
Digitalized BOMs Digitalized Bills of Materials automatically imported from SAP virtually eliminated wrong material deliveries.
Optimized feeder routes Line feeder routes are calculated, optimized and based on real-time data. That resolves both over and under deliveries to the line.
Changeovers performance The line changeover periods cross products were shortened significantly.
The solution approach The system utilizes Poka-yoke principles to prevent human failure and related delays. Customers can hit their plans in less time, downtimes rate was significantly lowered with further reductions of direct staffing costs and downtimes-related loss.
Satisfied customer is all that matters at the end of the day.
Adrian, Supply Chain Manager
„I have worked extensively with AP soft over the last few years to support the expansion and development of our manufacturing execution system. AP soft has continued to deliver and listen to our needs and requirements first hand and worked closely with us to fulfill our vision of how things should operate.
The introduction and development of the Milkrun has been a major success story for shaping the logistics transformation on site. The Milkrun aids understanding of parts usage directly from the PAM giving greater visibility of parts requirements whilst also assisting the line feeder in preparation. By having it live on the tablet and fully integrated into the truck the line feeder is better prepared and in control of material supply to the track.
AP soft‘s approach is both professional and customer-centric. Overall project engagement is excellent as well as responsive and we know that the team is only a phone call away to pick up any problems we may have.“
Frank, Group Plant Manager
„As one of the world‘s market and technology leaders we had needed a strong IT partner. AP soft has been a real partner. Their help was quick and effective. They are natural professionals.“
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