Marketed under the trademark Grohe, the Grohe Group is a leading manufacturer of sanitary fittings, focusing on quality, technology and sustainability to provide “Sheer Enjoyment of Water.“ The Grohe Group employs about 9,000 employees worldwide, with approximately 2,300 employees located at sites in Hemer, Lahr and Porta Westfalia in Germany and has generated consolidated revenue of about 1.4 billion Euros. Grohe manufactures in nine locations worldwide: Thailand, Portugal, Canadaand China (Joyou). In Germany alone, the company achieved 15 percent of their total revenue with products for kitchens and bathrooms, the commercial and public sectors, installation and flushing systems.
Jürgen Durhack, Applications-/Consulting- Production, Grohe AG
We decided to take on board MPDV as a strategic partner, having obtained standard MES software, which could be adapted to our requirements. Using HYDRA ensures transparency in all production areas. We employed standardized interfaces by MPDV to connect to our machines and facilities and to the SAP system.
Producing fittings and fixtures consists of the following basic steps: casting the molds, machining, surface finishing and final assembly. Data is to be collected over the complete processing chain. Also, the procedure is to be planned and controlled efficiently. Perfect utilization of tools and machines are the main focus.
In order to manage all the assigned tasks, Grohe relies on the Manufacturing Execution System HYDRA by MPDV in all three German sites. Tooling, core molding, casting, machining, electroplating, injection molding and installation are connected to the MES system. A very specific aspect is the interface to the Arburg control system which is run as a subsystem. HYDRA collects piece numbers and machine conditions automatically. The operators enter their orders on the terminal and give reasons for extended downtimes. Where manual work is carried out, Grohe AG quantities are collected by operating simple keys. To evaluate and illustrate collected data, Grohe uses HYDRA functions and their own connected applications. Essential information is available for the operators via big screens. Machines and tools are perfectly utilized using detailed planning and integrated in HYDRA without building up nonessential stocks of work in progress. Direct connection of machines enables a person to react quickly to malfunctions and bottlenecks. Available capacities are identified in time and can be used for replanning.
Overall, the HYDRA MES solution increases transparency and efficiencies in their production by collecting and evaluating hard data in real time.
To round up the functional scope, Grohe also uses HYDRA Time & Attendance and its integrated Access Control system. Currently, Grohe is switching to HYDRA 8.
- Windows Server and MS SQL database
- ERP interface to SAP, Arburg-Leitsystem (ALS) connected as subsystem
- 120 HYDRA Shop Floor Clients
- 60 HYDRA Office Clients
- 330 connected machines