The term “smart manufacturing” is usually used in the context of machine-based, networked manufacturing. With your “Track & Trace” development, you have shown that artisanal manufacturing, i.e. what “manufactory” describes in its origins, also has the potential for optimization. In which area of custom manufacturing do you think this potential is greatest?
Uwe Wagner: Definitely in production control and material logistics. The amount of material in circulation in production can be significantly reduced with our solution, and transparency is created with regard to individual orders.
As a result, it is possible to significantly reduce the liquidity tied up in circulating stocks. Saving effects of several 10 TEUR to clearly more than 100 TEUR are possible. This capital gained can be used by manufacturing SMEs, for example, for investments in machinery and equipment as well as in automation and digitization!
Where exactly does your newly developed “Track & Trace” solution come in?
Uwe Wagner: With the help of our smart system, throughput times in production can be significantly reduced. Another advantage is picking according to demand. Thus, a considerable optimization of the production of upstream processes can be achieved and the effectiveness can be increased. The idea of “pulling” from lean management is implemented with this solution.
What can the IoT kit do?
Uwe Wagner: A visualization clearly displays the material requirements to the employees of the upstream processes. Based on this demand message, the employees can independently pick the required resources and make them available again at the appropriate point in production. This targeted provisioning can save a considerable amount of space, as the circulation and material stocks in production are significantly reduced.
Feel free to take us inside the technology behind the solution here. What are the individual components?
Uwe Wagner: Technically, the system consists of various sensors with wireless communication. These radio-based, robust parking space sensors can be easily installed and individually configured. In addition to the parking space sensors, data can also be provided for environmental monitoring (temperature, humidity, pressure) and for media monitoring (gas, electricity, water). All information is collected in a central gateway, where it is processed, evaluated and graphically presented. The data can be evaluated via XLS, Grafana or also via app. The process flow is optimally visualized with a dashboard and can be shown on displays everywhere. Analysis options for cycle times are also provided.
Companies often struggle with completely rethinking processes. What was your reason for saying, “Now something has to change fundamentally in our processes”?
Uwe Wagner: We also had a lot of understanding problems for a long time during the introduction of lean management. And that was despite various training courses and advanced training. Central production planning was accompanied by many emails, agreements, escalations and cross-communication. Our goal was to eliminate these unproductive and demotivating processes, shorten communication paths, and transmit information faster, in a targeted manner, and without errors. And empower our employees to act on their own.
How long did the entire implementation process take?
Uwe Wagner: From the initial idea to the current implementation took 2 years, the realization of the parking space monitoring 2 months.
Today, we can install the system at the customer’s site within 1 day and after only about 1 week, the processes and actions of the employees change.
What was the biggest challenge during development and how did you keep your team on track?
Uwe Wagner: In the implementation of the interaction of hardware and software as well as the realization of the whole chain – from data acquisition to archiving and display.
What are the measurable results and what is the biggest benefit for you personally?
Uwe Wagner: Our biggest benefit is definitely the reduction in throughput time in production due to the significant reduction in walking distances for employees. This has also significantly reduced our circulating stocks. And we have saved a lot of space. There are a lot fewer production orders sitting around (reducing buffer inventories). This has enabled us to achieve our growth in the same production area.
In which areas and industries could your IoT kit still find application?
Uwe Wagner: It could definitely also be used in cycle time recording and predictive maintenance.
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Managing Partner / CEO
Phone: +49 351 430 39 – 30
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DELTEC electronics GmbH
DELTEC electronics is the creative generalist for electronic system assemblies. Our portfolio ranges from electronics development, printed circuit board assembly, cable assembly and device construction to IoT solutions. With currently 65 motivated employees, modern equipment and a QM system on level ISO 9001 and 13485 we can achieve highest quality. From support in hardware development & redesign, prototyping to series production at our location in Dresden-Gittersee, a lot is possible.
Our decisive advantage is our complete offer of development, prototyping, manufacturing and material logistics with a deep added value in electronic systems. With 30 years of experience in the market, DELTEC electronics stands for partnership, flexibility and profound customer understanding.
Heidelberger Str. 18, 01189 Dresden, Germany
Phone: +49 351 430 39 – 30
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