RUCH NOVAPLAST GmbH + Co. KG is one of the large European specialists for the development and production of foamed pieces made of expanded polystyrene (EPS) and expanded polypropylene (EPP). The company perceives itself as a supplier of systems and development partner for the industry. An in-house team of engineers develops innovative solutions for packaging, load carriers, automotive parts, protective padding, robot trays, insulation and molded parts for leisure industry.
Mathias Schmälzle, Head of Controlling and responsible for the introduction of HYDRA
Using MES systems is for our employees in production as naturally and indispensable as the ERP system in administration. The MES HYDRA offers all functions to control and monitor our production. Productivity KPIs are automatically generated by the MES. During the last 24 months, we have improved our OEE index by more than 15%. That means a savings potential of several hundred thousand Euros. Therefore, HYDRA has been amortized in a very short time.
RUCH NOVAPLAST realized very early the advantages of collecting shop floor data and machine data and used a simple but now „obsolete“ system. In 2009, the company looked for an integrated Manufacturing Execution System (MES) which is able to cover all requirements in one system: shop floor and machine data collection, batch tracing, collection of quality data and recording of working hours and access control. Also, the system was required to be directly connected to the ERP system Microsoft Dynamics AX and the MES supplier should be able to guarantee investment reliability.
MPDV was chosen after an extensive selection process. Departments involved with the MES system were included in that process, in order to safeguard an acceptance of the system. MES HYDRA already covers in the standard version the required evaluations. With HYDRA every member of staff can view the current machine status at all times – in the production halls, one can see the machinery on a 46“ display showing the individual machine statuses. If critical machines are not working, counter measures are prompted instantly. Lists to change setup of tools ensure preparation of machines in good time. The HYDRA module for Material & Production Logistics is used to document traceability. Additionally, HYDRA carries out quality inspections from goods-in to goods-out. In future the use of electronic control charts is planned.
Using HYDRA Energy Management, RUCH NOVAPLAST can analyze energy consumption related to orders and therefore introduce specific optimization measures.
In 2012, the old system to collect working hours and time management was replaced by the HYDRA modules for Time & Attendance (PZE), Personnel Time Management (PZW) and Access Control (ZKS).
In 2013, the system was successfully rolled out to the site in the Czech Republic (MORAplast s.r.o.).
- Interface to Microsoft Dynamics
- 20 evaluation and planning consoles
- 12 Industrial PCs with touch screen
- 32 injection molding machines connected via UMPS
- 5 scales connected via the Process Communication Controller (PCC)