Digital transparency and efficient production control
STOBAG AG
The challenge - digitalization and scaling of a growing production site
STOBAG is an internationally active Swiss manufacturer of high-quality sun and weather protection solutions. With the large-scale expansion of the production site in Sülysáp, a central production site of STOBAG in Hungary, the company is pursuing the goal of significantly expanding capacity and raising production to a new technological level. The modernization includes the construction of several new production halls, the introduction of additional production lines and the use of modern surface and coating technologies. This will not only increase the production volume, but also the variety and complexity of the manufacturing processes.
With the help of a modern and self-expandable MES platform, production is to be seamlessly digitalized from detailed planning to packaging in a single system. The platform must connect existing and new machines and ensure the exchange of information with the ERP system.
The implementation - end-to-end integration and digital production control with iDIP
The following main functions were implemented with iDIP as part of the project:
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ERP integration: Automated transfer of all production orders, materials and material images from SAP for end-to-end digitization of production data.
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BDE & store floor integration: Standardized production data acquisition with automatic SAP feedback and centrally controlled label printing for all workstations along the entire production line.
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Day-optimized production planning: Day-based, colour-optimized order planning with the aim of minimizing colour changes on the powder coating system; in addition, the orders are intelligently distributed to the two sawing lines in order to optimally control throughput, sequence and system load.
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Planning the sawing lines: Optimization of profile cuts for maximum material utilization, supplemented by digital remnant management for reusing remaining profiles and automatic generation of material and transport orders in SAP.
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Saw connection: The profile-specific sawing parameters and the end stop are automatically transmitted to the saw via an OPC UA interface.
- Powder coating plant: Digital mapping of the entire plant with acquisition and transmission of process and status data via OPC UA as well as integrated powder management including automated SAP postings.
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Small parts picking: Guided picking of multiple orders simultaneously, supported by stationary and mobile devices with direct feedback to SAP.
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Handling unit management: Consistent management of mobile and fixed handling units for transparent traceability of every component along the entire material flow.
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Rework management: Possibility to trigger a structured rework process from any workstation, including digital recording of the reasons and automatic assignment of the affected components.
The result: end-to-end transparency, greater efficiency and future-proof processes
With the introduction of iDIP, STOBAG was able to comprehensively digitalize its production processes. Production orders, material data and feedback are now controlled centrally, eliminating media disruptions and creating a high level of transparency throughout the entire production process. Colour-optimized production planning and the intelligent distribution of orders to the two sawing lines ensure stable processes, fewer colour changes in powder coating and optimum utilization of the systems. In addition, profile optimization, digital remnant management and the automatic transmission of profile-specific sawing parameters minimize material consumption, reduce waste and increase cutting quality.
STOBAG has a scalable, future-proof MES solution that both supports current operations and optimally prepares for the further expansion of production. Further developments and process adjustments are carried out independently.
"With iDIP, we have created a flexible platform that we can develop further ourselves as a team. The close integration into our SAP processes enables us to implement improvements quickly and efficiently directly from operations."
Kai Gräff, Project Expert IT & Digital Business, STOBAG
Integrationspartner
We implemented this project together with our integration partner ITficient
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