GEDIA Automotive Group develops and processes stamped body parts, welded assemblies, safety and crash protection components for the automotive industry. The company was founded in 1910 in Attendorn and has an annual turnover of around 400 million Euro. GEDIA employs more than 2,600 people in seven production sites in Germany, Spain, Hungary, Poland and Mexico. High technical innovation, a continuous process optimization as well as a solid business model and a customer- oriented organization have secured success and growth. Modern production technologies, such as state-of-the-art panel transfer, pressing systems and automated forming processes as well as an in-house tool development are the foundation for many innovations to form steel and aluminum parts. In order to comply with ever increasing quality requirements, the company has been certified to ISO TS 16949 based on the DIN EN ISO 9000 standard. Their international customers are companies like Ford, Opel, VW, BMW and AUDI.
Uwe Hermann, Head of IT/Organizationat GEDIA Automotive Group
For many years, GEDIA has been relying on the MES system HYDRA. We use different modules close to the standard. In contrast to conventional shop floor scheduling or MES systems, HYDRA has a clear advantage which is that from planning to process optimization everything is done promptly and close to production. Especially in the automotive sector using dynamic processes, flexibility is of the utmost importance. HYDRA is highly accepted across all employees in production which is a great advantage.
As a connection between ERP, HR and production, a modular application package was required to increase machine and personnel capacities, to obtain evaluations based on real-time data and to optimize planning. A requirement was to use as many functions from the standard as possible.
GEDIA now uses the MES solution HYDRA as sub-system to SAP. Production orders from SAP are transferred to the HYDRA Shop Floor Scheduling module in order to do the detailed planning on shift levels. Then, HYDRA specifies which order is processed in which shift and on what machine. Users can view the progress of orders online by means of the HYDRA Shop Floor Data Collection module.
To collect order and machine data, numerous PCs and terminals are used. Additionally, more than 290 machines like presses, die cutting machines or welding robots are directly connected to HYDRA. The MES HYDRA is used by the management, production managers and supervisors on 160 PCs to issue individual reports and evaluations like shift reports, downtime analyses, utilization rates, etc.
The data collected by the module HYDRA-LLE (Premium & Incentive Wages) is used by GEDIA as the basis to calculate incentive wages. The integrated HYDRA Access Control ensures, that only authorized personnel has access to the sites.
GEDIA is successfully using the MES HYDRA across five locations in Germany, Spain, Hungary and Poland. Another roll-out for Mexico is planned.
- Windows server with Oracle database
- Interfaces to SAP (PP, PS and HR)
- 160 HYDRA office clients
- 281 HYDRA Shop Floor Clients