ROLEC from northern Germany is a manufacturer of enclosures for industrial electronic applications, command enclosures and suspension arm systems. In the medium-sized family company, 120 employees produce about 2,500 enclosures per day. Most of the enclosures are produced in small series or as single units. The company‘s particular strength is the production of customized, ready-to-install enclosures, from drawing to coating – with delivery times of two to three weeks and sometimes even 48 hours only. This is possible thanks to an ultramodern machinery, highly qualified employees and an extensive raw material warehouse. Another trump card is the passion of the management team – and the Manufacturing Execution System (MES) HYDRA.
Matthias Rose, company owner and managing director of ROLEC
Somehow we managed to deliver on time before the introduction of HYDRA. The effort is less today. Now we know what we have to expect.
The managing director, Matthias Rose, is a man who does not like to put things off. When he sees a problem, he searches for a solution and implements it; immediately, if possible. In the 31 years since its foundation by Matthias Rose and his father, ROLEC has become a market leader in the segment of high-end applications with innovative and partly patented solutions for electronic enclosures. The prompt implementation of customer requirements is one of their strengths. During the HYDRA implementation process, Matthias Rose pursued a similar approach: identify problem, check solution, start implementation. Four months after Rose signed the contract with MPDV, HYDRA was running in production.
"We were already working with an ERP system, but we needed more transparency in production," explains Rose. ROLEC processes about 1,500 different orders per month. "We knew when a job started and when it was finished. In between, things were far from clear." Other companies recommended the Manufacturing Execution System (MES) HYDRA. So Matthias Rose and his production manager, Stephan Fahrenkamp, attended an MPDV event in Bielefeld in December 2017. Right on the same day, he arranged a presentation meeting with an MPDV Account Manager.
Before deciding in favor of HYDRA, Rose wanted to make sure that the interface to the ERP system would work without problems. This was clarified in a workshop in January 2018. During this workshop, all external and internal persons responsible for ERP and MES got to know each other. "I would do it again", says the managing director. "All contact persons got along very well and then communicated directly with each other." At the end of March, the HYDRA implementation was started. Since the go-live on July 4, 2018, all shop floor and machine data has been collected with HYDRA. In November 2019, the ROLEC site in Portugal was connected to the MES. "Since then, it has been as if we were producing in the room next door," Matthias Rose points out happily.
The broad acceptance among the employees paved the way for the rapid implementation of HYDRA. 115 employees at ROLEC use HYDRA. 34 worker terminals are available in production. 11 PCs are used as HYDRA office clients by 14 users. The employees were briefed in training sessions. Shrink-wrapped operation instructions at the worker terminals are used as reminders. The production manager, Stephan Fahrenkamp, was responsible for the project. He was supported by the work scheduling manager. "There was hardly any scepticism," reports Fahrenkamp. "Some of the employees had questions. We answered the questions and that was it." The employees have access to the data and can see the information that is collected about themselves.
"My daily routine has changed a lot since HYDRA," says the production manager. "I used to spend a lot of time on the phone to catch up on the status of the different orders. Today, I only have to look at the screen." The same is true for the other heads of department. They used to prioritize the things that were directly in front of them. Now, HYDRA provides a reliable basis for work scheduling. And also the managing director, Matthias Rose, does not want to do without the MES anymore: "HYDRA can make us faster and more flexible in the future."
- 120 employees
- 35 machines machines are connected to HYDRA
- 15 HYDRA shop floor clients
- Interface to the ERP system „Microsoft Dynamics AX“