Introduction of an MES system
At the manufacturing plant in Zeulenroda, a new system for production data acquisition (PDA) is gradually being introduced. This offers a great deal more functions than the previous version from 2005 and is a Manufacturing Executive System (MES for short). This means it is a holistic solution for analyzing and controlling production processes. Manufacturing data were previously recorded at static PDA terminals and generally were only available for analysis using Excel on the following day. But now the MES tool “SAP MII” enables more extensive and considerably more precise data acquisition. “This allows us to improve the control of manufacturing processes and take action more rapidly. In particular, our team leaders will benefit from this,” explains Lars Eulitz who is managing the project. One example: “If production is faulty at one machine, we can detect this in real time. In this way, we can prevent any further defective products.” This is made possible by a much larger number of devices. These include new monitors along with mobile devices in smartphone format that can be brought along to every workspace. Every work step is displayed digitally on these devices. For example, the current status of an order can be seen along with accompanying documents for processing.
The system was introduced in June for the circular knit areas. By the end of December, all planned functions should be available. In-process tests that were previously managed manually will then be carried out digitally using the tool. “The new software solution is an important milestone on the way to digital manufacture, and will be rolled out next year at all production areas in Zeulenroda and Gera,” remarks Lars Eulitz.
New organizational structures facilitate manufacture
“Over the next weeks, we will conclude the reorganization of the supports manufacturing team based on the system of product management according to parts of the body,” says Marcel Sicheneder, Operations Manager at Zeulenroda. The team led by Annett Baum (BK2) will manage hand, foot and elbow supports, the team led by Yvette Hammerschmidt (BK4) will manage thigh and knee products, the team led by Beate Täubert (BK6) will manage back and shoulder supports and the team led by Kerstin Gerold (BK7) will manage b:joynz and sports supports. “Thanks to the new system, contact between the team leaders, product managers and product developers has been intensified.”
New shift times
The introduction of the 39-hour week in December will bring new shift times, and smiles to many employees’ faces. They were previously used to “regular” working hours and will now start with a 2-shift cycle starting at 5 a.m. for the early shift that goes until 1:33 p.m. At this time, the late shift will start seamlessly, ending at 10:06 p.m.