Koziol has been producing plastic articles since the 1930s. Production takes place exclusively at the company site in Erbach, Germany. The vertical range of manufacture is considerable. The spectrum ranges from design, development, construction, mold making, production, and shipping to administration. Koziol is also committed to the environment and has been producing solely with green electricity since 2013.
Thomas Heidorn, responsible for production planning
Thanks to MES HYDRA by MPDV, we have managed to convert our production to respiratory mask without any problems and to coordinate all processes optimally. Now we can produce as many respiratory masks as required in the shortest possible time.
Special times require special measures. This is why Koziol, a company from Erbach, in Germany, has been producing respiratory masks since April. Employees at Koziol use MPDV‘s Manufacturing Execution System (MES) HYDRA to plan and control production orders and thus guarantee a smooth production process. Koziol normally manufactures drinking cups, mixing bowls or cutlery from 100 percent recyclable plastic. Following the corona crisis, the company has recently changed its production and now manufactures reusable respiratory masks made of thermoplastic elastomer. This is a special plastic that is particularly flexible and can be cleaned with soap and water. Koziol produces more than 3500 respiratory masks daily in addition to its actual business. Goes without saying that every cog in the works must mesh perfectly. „We have no time for production downtimes.“ says Thomas Heidorn is responsible for order planning at Koziol.
Getting the most out of it
MPDV‘s MES HYDRA monitors the entire production process. For example, HYDRA shows exactly how many respiratory masks have already been produced in pink and when the next color change is due. With HYDRA Thomas Heidorn also knows when tools require maintenance. „This is a great advantage as the system enables us to plan in advance and use this time to service machines in parallel. Special tools are used to manufacture the masks and only a limited number of them is available. After all, Koziol designed the masks within three weeks and at the same time built the tools themselves. Heidorn‘s task is to ensure that each tool is in the right place at the right time and that production does not come to a standstill. Thanks to HYDRA we have a complete overview and the system allows us to make the most of our resources.“
The engine for production
32 injection molding machines are connected to the MES HYDRA. Heidorn can see on the monitor in his office exactly how many parts are being produced by which system or are currently at a standstill. „This overview is great. HYDRA has increased the transparency in the shop floor enormously. The MES has also enabled
us to smoothly convert our production to protective masks and to perfectly coordinate all processes. Now we can produce as many respiratory masks as possible in the shortest possible time. Without HYDRA this would certainly not have been possible“, says Heidorn with great delight. Koziol uses HYDRA for all areas. Their internal printing press is also connected to HYDRA. This allows Heidorn to see early on order gaps in the print shop and how he can use them effectively for other productions. The external installation service of Koziol will be connected to the MES HYDRA in the near future. „With HYDRA we keep an eye on all areas of our production and avoid idle times.“ Plans for the future include the use of other MES HYDRA functions, for example monitoring temperatures during the processing of raw materials. After all, working with plastic is all about precision. Heidorn knows that very well. He has been working for Koziol for more than 21 years.
- ERP-/PPS-Software: Sage bäurer B2
- Server and database: Microsoft Server with MS-SQL database
- 12 evaluation and planning consoles and 4 IPC terminals with touch screen with one data collection station per machine
- 28 injection molding machines
- HYDRA-HLS, HYDRA-BDE, HYDRA-MDE
- Interface to the ERP system Sage bäurer B2