Predictive maintenance
A global company specializing in drive technology and industrial automation, with branches in over a dozen countries. The project, carried out at two locations — in Poland and Austria — involved the modernization of assembly processes, logistics, visitor registration, and quality reporting.

Business challenges

In a dynamically developing industrial production environment, the company aimed to:

  • Increase work efficiency at assembly stations
  • Shorten the time to handle production errors
  • Enhance employee engagement in continuous improvement (kaizen)
  • Simplify management of complaints and quality documentation
  • Automate logistics and shipping processes
  • Centralize visitor registration and fire protection (PPOŻ) reporting

Scope of implementation and transformation

Digital assembly support with RFID technology
A system for identifying trays with components using RFID tags was implemented, enabling the automatic display of assembly parameters, 3D models of assemblies, and technical documentation retrieved from SAP. This solution significantly accelerated onboarding of new employees and completely eliminated paper documentation.

ANDON system — quick response to issues and improvement ideas
An integrated system for reporting production errors and near misses directly from workstations was introduced. Thanks to integration with light signaling systems, calling the appropriate employee became immediate. Expanding the system with a function for submitting kaizen ideas, combined with a reward mechanism, greatly increased employee engagement.

Integrated quality and complaint management
The system enables quick assignment of errors to specific components and assembly orders, fully integrated with SAP. As a result, the time needed to prepare complaint documentation and quality reports was significantly reduced.

Logistics automation and integration with freight carriers
Mechanisms were implemented to generate shipping orders directly based on SAP data. Integration with Schenker and GLS systems accelerated logistics processes, reduced data transmission errors, and shortened the time needed to handle shipments.

Visitor registration and access management
A modern self-service guest registration module not only collects the required data (e.g., for fire protection compliance) but also presents the necessary declarations and safety documents. These data are integrated with the access management system and used to generate standardized fire safety (PPOŻ) reports.

Room reservation and occupancy information
Terminals by the meeting rooms and information monitors display real-time room booking statuses, integrated with a Microsoft Exchange-based calendar. Additionally, informational content and safety principles for the facility are displayed.

Business outcomes

faster error and incident reporting
0 %

thanks to intuitive interfaces and SAP data automation

shorter shipping process time
10 %

due to full integration with carrier systems

faster preparation of quality and complaint reports
60 %

with full access to component and order history data

Industry
Industry
Processes
big datacyber-physical systemsinteroperabilityMESpredictive analyticsRFID
Processes
big datacyber-physical systemsinteroperabilityMESpredictive analyticsRFID

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