Bezpapírová výroba v praxi aneb další kroky k průmyslu 4.0 ve (3. strana)

BUSINESS Paperless Production in Practice Further Steps Towards Industry 4.0 in Dormer Pramet The Dormer Pramet company intensively innovates and optimizes their processes. For the management of the whole company, including production, uses SAP system and has already for some time been considering further digitalization of production. The company’s experts, together with experts from S&T, have prepared a detailed concept where they have mapped all the fields and designed a solution. Dormer Pramet is an important global producer and supplier of machining tools. Its wide product range includes both plate tools, which are produced in the Šumperk production plant, and monolithic rotational tools, which are mostly produced in sister plant in São Paulo, Brazil. The company provides wide range of sales and technical support via its network of more than twenty dealerships. Deliveries are managed by a top level distributional and logistic network which uses several distribution centers on every continent. Collection of shopfloor information without connection to the machines does not allow fast status update; it is largely dependent on the human factor and it also limits the amount of information that can be tracked this way. On shopfloor management side, printing instructions costs time and money and printed information cannot be updated easily. But is it even possible in to get rid of paper completely? Will it decrease efficiency or knowledge sharing? With concept of paperless production - can all necessary information flows be achieved from instructions and manufacturing documentation through various supportive records to quality management documentation? The proposed goals can be summarized into four digitalization areas, where using SAP tools from S&T will help to make production management easier and more efficient. PROVIDED BENEFITS: Substantial reduction of paper documentation Up-to-date information for everyone Easier production reporting Real-time tracking and more precise registration of the tools and fixtures lifetime Visualization of workcenter statuses Paper documentation in electronic form, always up to date Paper documents - orders, guides, routings - were used in the workshops for management and tracking of production. The goal was to replace the paper documents with electronic ones as much as possible and thus ensure that the documents will be available faster and always in the right version. 24 ǀ POSITIV 4/2020 How does the situation look after the implementation of this solution? The necessary documentation is in an updated form available online, directly on the operators’ tablets. Additionally, in digital form are available also the final documents for quality tracking, for traceability of components and responsibility. Digitalization and easier production reporting Production reporting was done originally via PC-shopfloor operators and technicians entered their reports of produced pieces directly into the SAP system. The new goal was to perform production reporting on mobile tablets, with simplified applications for easy operation and with ability to read additional information directly from the workcenter controller units. This way, all the necessary information will be collected in real time and on one place. This goal was also fulfilled: the production reporting is done efficiently with use of new applications. A maximal amount of information is collected automatically—according to user login to the workplace and the order, and also by direct usage of information from controller unit of the machine. The result – achievement of maximal freshness of information. At the same time with bigger volume and accuracy of the data, the data entry is now less demanding for the user. It is possible to analyze production costs better, to flexibly manage production process and related stock. Real-time tracking of location and remaining lifetime of tools Tracking very expensive tools, which are necessary for production, is an important topic in Dormer Pramet. The tools with fixtures are located in the storage cabinets or directly in the toll-containers of the given machining center. So far, the actual usage and location of tools with fixtures was not tracked in the system. The remaining lifetime of the tools was registered manually on paper labels next by each tool. Important goal of the new solution was realtime electronic registration of the current location of the tool and fixtures, independent of manual input, as well as tracking of the remaining lifetime of the tool. Both captured directly from the workcenter.