Hansgrohe is one of the few global players in the sanitary sector consisting of 34 companies and 21 sales offices. In 2016, the business had a turnover of 1,029 Mio. and more than 4,800 employees worldwide. The company is headquartered in Schiltach, Germany. was founded in 1901 and has earned a reputation within the sanitary industry as one of the innovation leaders in technology, design and sustainability. Kitchen and bathroom faucets, shower heads and complete shower sets by Hansgrohe SE are made to increase the functionality and comfort in bath and kitchen.
Thomas Schüßler, Vice President Production Hansgrohe SE
Our plan to combine the introduction of HYDRA with our evolving shopfloor management has proven successful. HYDRA is a vital tool to obtain information and to control production for all employees. We cannot imagine our daily routines without HYDRA.
In 2012, Hansgrohe issued a tender for a Manufacturing Execution System (MES) to achieve four main goals:
- Increasing transparency and reactivity in production
- Reduction of waste and idle times
- Implementation of an efficient shop floor management
- Facilitating planning processes and increasing process stability
After a pilot phase, Hansgrohe gradually introduced the integrated Manufacturing Execution System HYDRA by MPDV to the sites in Offenburg/Germany, Shanghai/China and the headquarter in Schiltach/Germany.
The following modules were installed: machine data (MDE), shop floor data (BDE), DNC & configuration data (DNC) and shop floor scheduling (HLS).
The collected machine data are mainly used in the evolving shop floor management. Besides printed reports and graphics 14 monitors installed in the production hall provide information on current KPIs. This guarantees that each employee is updated on events in production which promotes employees motivation and sense of responsibility for their own working area. Integrating shop floor management in the company-wide improvement process (CIP) safeguards that all optimization measures are followed up.
The additional collection of order and shop floor data provides more transparency. To this end, production orders are downloaded from the SAP ERP system, planned and processed in HYDRA and uploaded again to the ERP system. Hansgrohe now has a valuable tool to optimize its production planning. Confirming real-time data from the shop floor enables planning against real capacities and guarantees reactivity and production control. Interruptions and unplanned events are detected immediately and quickly rescheduled to keep delays at a minimum.
To facilitate setup processes, Hansgrohe uses HYDRA DNC for transferring configuration data (e.g. for injection molding machines and handling robots). This reduces efforts and avoids errors during the setup as HYDRA secures the transfer of correct data to the machine. MPDV designed a specific driver interface to accommodate some of the robots.
The location in Schiltach has already carried out a pilot installation with HYDRA to integrate quality assurance (CAQ). A further test run for HYDRA process data (PDV) is anticipated. Hansgrohe‘s long-term plans are to use HYDRA modules across all areas in every site.
- MS Windows server with MS SQL database
- Interface to SAP-ECC 6.0 (PP-PDC, HYINFO)
- approx. 60 HYDRA office clients
- approx. 75 HYDRA shop floor clients (BDE terminals)
- 14 on-site monitors
- 109 machines connected