Results of the Project
“Our new MES system lays the foundation for the successful future of Vorwerk Autotec. Improving transparency in production, the value chain, and logistics is the basis for future productivity increases. Key components of the system include: real-time data in SAP ERP, reduction (elimination) of manual posting processes, high automation, and consistent design of the system for global use.”
Dennis Dünnweg, Project Manager, Vorwerk Autotec
Vorwerk
The whole story
Vorwerk – The Customer
Worldwide , renowned carmakers rely on quality products from Vorwerk & Sohn . As leading innovator in suspension technology , system components and materials ,Vorwerk & Sohn provides customers with solutions that are ahead of their time . First-class products – this is the goal of the Vorwerk & Sohn group . The requirements of the automobile manufacturers set the benchmarks for the company.
As part of the Vorwerk & Sohn group, Vorwerk Autotec is specialized in the development and production of high quality chassis bearings for the automotive industry . The quality of materials used and their processing in production are their main focus.
The Challenge: At a glance
Vorwerk – The challenge
Bodywork transition and pass-through elements, tubes for ventilation or liquids, these are the products of Vorwerk Autotec. The components are manufactured in Germany, China, Mexico and Poland. International production locations facilitate cost-efficient and rapid execution of customer projects.
Vorwerk Autotec production processes were not completely optimized yet. As there were only a few pieces of real-time data available from production, neither the current status of production was completely accessible nor was process data.
The opportunities of real-time production data analysis and calculation in SAP have not been used so far. Postings of activities and material stocks have been processed with delay.
Vorwerk
Integration of BDE platform with SAP within 6 Months
Vorwerk– The Project
This was about to change by connecting the MES platform from Global C Software, which collected production data from 135 machines, to SAP ERP in real time.
The goal of the project: to make more effective use of the capabilities of both systems. In addition to increased transparency, targeted analysis as well as a further automation of production processes should be implemented. About 1000 containers for production supply and production disposal are transported between stock and production every day by forklifts. There are ca. 40.000 accounting transactions for material movement in manufacturing, mostly in one-piece-flow. These material movements and production processes as well as production execution were planned to be optimized and accelerated.
Increased transparency in production at Vorwerk Autotec
The rollout of the solution happened step by step. At first, the PDC interface was realized at the location in Wuppertal. Afterwards, the optimizations were rolled out and adapted to the regional specifications at the locations in Brodniza (Poland) and Suzhou (China).
Dennis Dünnweg, project manager at Vorwerk, is more than satisfied with the results of the project:
“With this project, Vorwerk Autotec has taken a big step towards Industry 4.0”