Diehl Foundation & Co. KG is one of the large, German enterprises operating internationally. The company is family-owned since its foundation 100 years ago and employs 10,500 staff worldwide. The subgroup Diehl Metall is one of the leading suppliers for the automotive, heating, sanitary, electronic industry, manufacturing in its German locations Röthenbach/Peg and Sundwig as well as in its subsidiaries in Brazil, USA, France and China. You can find semi-finished and forged components made of brass and innovative special brass alloys by Diehl in many areas of everyday life. The company division Forging Technology is one of the leading producers of drop-forged parts made from a brass alloy and is a worldwide expert for special applications like synchronizer rings for gearboxes. Diehl products are also used in almost every household as sanitary and gas fittings. Diehl Metall generates a turnover of 421 million Euro with 2,450 employees.
Dipl.-Kfm. Bernd Matejat, Head of Personnel IT Systems, at Diehl Metall
After a successful implementation, the system has been continuously upgraded. New tasks resulting from enormous production utilization and the need for information could be successfully solved.
Replacing an existing time recording system, Diehl wanted a new, flexible and fail-proofed one which could still be used when, at a later stage, SAP was implemented. They also needed a system containing a certified interface to SAP. The new PZE module should also fulfil requirements stated in the company agreement for flexible working hours.
Requirements to the BDE module were focused on online information for the total production level, simplifying working procedures, supporting initiatives for a paperless production and machine data collection.
The HYDRA project at Diehl started with a detailed definition for the requirements specification. In April 1997, HYDRA was gradually implemented starting with a PZE test run which was followed by a pilot phase of BDE and MDE at the end of that year. Three months later, HYDRA was productively used at more than 60 workstations. Following, HYDRA was systematically upgraded by integrating weighing systems by Mettler Toledo, modules for Shop Floor Scheduling, Personnel Scheduling and Incentive Pay. Currently, the module Material & Production Logistics is being added to their system. This project should be completed by 2010. HYDRA reduces the manual input efforts in administration and ensures transparency by showing current order, personnel and machine statuses. This is supported, for example, by directly connecting the BDE module to weighing systems and machines, which allows for exact piece numbers/ quantities to be uploaded to SAP PP.
- 2 servers with Oracle databases
- 73 terminals (IPCs and PCs with touch screen) for BDE and MDE
- 25 terminals for Time & Attendance and/or Access Control
- 230 HYDRA office clients
- Interfaces to SAP PP, HR, CO
- Interfaces to machine controls and weighing systems