Overview“Saves operating costs in the five-digit range”
Top MES solution for Benecke Kaliko
Early shutdown of the old system at Benecke-Kaliko. The future is called top MES.
The early shutdown of the old system will save operating costs in the five-figure range this year,” explains Jürgen Roth, Head of IT Management.
A truly successful launch for the new store floor data collection system in Hanover – and ahead of schedule!
The contact person responsible for the system at the company, Mr. Harald Zeidler, is relieved: “The frequent night and weekend work to clarify and resolve the old system is now a thing of the past.
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Benecke Kaliko AG, based in Hanover, is a developer and manufacturer of technical and decorative surface materials and moulded plastic skins. The global market leader in automotive interior film is part of the ContiTech Group. Benecke-Kaliko produces with more than 1500 employees at five locations.
Insufficient collection of production data, non-updated stock levels and failure to take quality data from production into account were the reasons for looking for a new PDA system. The decision was made in favor of the integrated top MES from top flow, a proven manufacturing execution system.
It was a particular challenge for the 30 or so team members to bring the old data into a new structure and to restore the current production orders in the new system to exactly the same state as they had before.
“It was only thanks to good preparation that the team was able to keep to the schedule so precisely that the new system could be put into operation on time for the early shift,” emphasizes Mr Roth.
The new system provides continuous and up-to-date information. All the necessary production data can be seen at the touch of a button: control cockpits show all the relevant information for production planning, external processing, mixing rooms and ideal sample processing as well as the machine status – this provides a quick overview of what is currently happening in production.
Extensive analysis and reporting functions, including an efficiency display(OEE), allow deviations and weak points to be quickly identified and rectified. To ensure that all these options are used correctly, the production employees were offered extensive training in advance, and in the first three weeks after the system went live, they were supported by the project team and top flow in three-shift operation on site.
How the individual departments benefit
In addition to the general advantages, users in the various departments benefit from the new system in particular ways. For example, the elimination of individual calculation processes in the mixing room reduces the susceptibility to errors. SAP confirmations are simplified by the coordinated user interface and stocktaking becomes clearer. In addition, the elimination of the old system means that there is now one less interface. All stocks are now visible in SAP and can therefore be better coordinated. Confirmations are displayed with actual values, correction postings are reduced and changes in parts lists are available immediately. Mixing orders are forwarded without waiting time. Work planning, production and the transport system benefit from the more stable system and performance improvements. All planning now takes place in one system. In production, roller ordering has been simplified and is now also carried out using just one system. A roller history is also available. Rollers, bales, error messages and the entire production process can now be easily traced. The system also provides clearer data with tolerance and intervention limits for quality management. The disappearance of interfaces also has a positive effect on the transport system. Changes such as the creation of new pallet colors can be made by the authorized users themselves. And thanks to the standard software, individual program changes are no longer necessary. An important advantage for controlling is that it is now possible to evaluate services in the mixing rooms. The posted actual quantities also make the billing of production orders clearer and also enable the billing of mixed orders.
The MES solution from top flow
The store floor integration solutions from top flow GmbH are the first of their kind to be based entirely on SAP technology. Subsystems, third-party technologies (black boxes) and interface problems are therefore a thing of the past. The integrated OEE analysis system provides the basis for increasing efficiency and contains all essential key figures for evaluating and optimizing production processes. The optional inclusion of SAP MII means that not only production data acquisition and machine data acquisition, but also extensive real-time analysis and complex business logic functionalities are available. The result is a highly functional top MES (Manufacturing Execution System) – based exclusively on SAP technology!
Some advantages at a glance
- Better adherence to deadlines
- Information on quantities and value of stocks
- The cost flow is traceable throughout the entire production process
- Significant reduction in the operating costs of the system
- Presentation of the overall system effectiveness
- Integrated quality, transport and warehouse management
- Elimination of subsystems and interfaces
Success Story top MES – Benecke Kaliko (PDF)
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