Industrie 4.0
A showcase project for Ersa
The intelligent networking of people, machines and industrial processes offers a complete dynamic system. Here at Ersa we use the “Industry 4.0” method to raise our productivity to a new dimension, actively shaping the future of industry.
Industry 4.0 is not bought off-the-peg like a software system or item of machinery, but must be developed in line with the process requirements for each operational and production procedure. Industry 4.0 is not a mass of information, but is based on intelligent linking, incorporating employee expertise, and it requires integrated lean and smart production systems. Industry 4.0 is a living, all-encompassing process, which has to be implemented in line with the individual needs of each company.
What we have already implemented:
- ICCS – Order configuration – SAP – Production
- Technical parts lists – Notification of requirements – Procurement
- Staged logistics – Final assembly
- Procurement – Preassembly – Final assembly – Testing/delivery acceptance in the form of an integrated Technical facilities ↔ Sales database
What we have already implemented:
- The production of binding, error-free, individually configured quotes in just a few minutes; quotation drawings, connection and user data, and shipping weight are presented together with the order in PDF format.
- A system used by all sales staff worldwide; in addition, approx. 30 sales partners have a representative’s version.
- At the quoting stage we can determine the production costs in minutes or reserve the machinery with the actual planned production capacity.
- Once accepted by the customer, the quote is transferred to our ERP system at the press of a button. The order generates the technical parts list requirement notifications and triggers procurement to meet the deadline.
- There are no errors resulting from incorrect configuration, the throughput times are substantially reduced, and the frozen zone is shortened by more than 50%. This makes us more flexible in our continuous flow production and enables us to optimise the systems to achieve a 10% increase in production capacity for the same number of working hours.
- The logistics are incorporated at each stage of the actual continuous flow production process.
- Overall, we have an integrated system from quote/order through the internal sales-order centre-purchasing and logistics, to preassembly, final assembly and testing/delivery acceptance.
- In a further stage, mobile data provision, from customer orders through to service billing, will be introduced in the first quarter of 2016.
- As of now, all our customers’ production machines are vertically integrated into a higher-level master computer system. At each stage of production the system knows where each flat pack assembly is located and which process parameters are applicable. Horizontal communication between the individual integrated and linked machines is currently only possible between the immediately preceding and subsequent machines in the series.
- If the capacity within the production line, relating to the provision of production elements, can be adjusted in real time (e.g. parts have not arrived due to delayed customs clearance for assemblies), individual machine elements can automatically be switched on the fly to maintenance mode, as the whole system can run on a lower production capacity.
Industry 4.0 opens up innumerable possibilities – now it is up to the people to decide what is important and what will be implemented!