Phoenix Contact is a worldwide market leader for components, systems and solutions in the field of electrical engineering, electronics and automation. Phoenix Contact has 13,000 employees with a head office in Blomberg (North Rhine-Westphalia, Germany) and various other production sites and sales offices. With a high level of vertical manufacturing, Phoenix Contact produces, apart from screws and bolts, polymer and metal parts, and a wide range of product components and system solutions for the tooling and processing sector as well as other industries. The components contain, amongst others, PCB, special purpose and terminal blocks, cable and plug connectors and automation devices based on Ethernet and Wireless.
Harm Hübert, MES Manager at Phoenix Contact
The HYDRA terminal gives us a significant point of information directly at the workstation. This point of information is multi-faceted and is being increasingly used to continuously improve our processes. Documents, order of material, production progress and quality statistics are now triggered or displayed at the terminal. A big step towards paperless production.“
Phoenix Contact is faced with managing and efficiently controlling a great variety of data, derived from complex multi-staged manufacturing processes. The integrated Manufacturing Execution System (MES) HYDRA by MPDV supports managers in fulfilling that requirement in various locations in Germany and Poland. Additionally, test or pilot projects are operating in China and in the USA.
Using the MES solution has, in a short period of time, resulted in much higher transparency in production and therefore improved productivity. Also, the quality of data, supplied by the ERP system SAP, is considerably better as HYDRA supports actual data and monitoring possibilities with detailed feedback. Based on detecting standstills of machines and the resulting statistics, measurements could be implemented to optimize machine and tooling availability. A fixed three-day production plan is generated combining HYDRA Shop Floor Scheduling with the module for Tool & Resource Management. This guarantees availability of all required resources for all the machines at the start of production due to timely information being available. The use of the DNC module simplifies the transmission of configuration data to injection molding machines. Secondly, important processing parameters are continually recorded and monitored. HYDRA also serves as a CAQ subsystem to collect, control, and measure values to further process in SAP QM.
Based on KPIs identified in HYDRA, responsible personnel can target monitoring processes and initiate improvements. Furthermore, costs are reduced and are detected proportionately amongst the departments.
- Windows server with ORACLE database
- Interfaces to SAP PP and QM
- Approx. 200 HYDRA Office Clients
- Approx. 900 connected machine and manual workplaces