The Weber Group is a systems partner for plastic solutions in the automotive, building and household appliance technology, heating and medical industries. With around 1400 employees, the mediumsized family-owned company develops and produces plastic components, modules and systems at locations in Germany, Poland and China. The company offers the entire range of project management services across all business areas – from conceptual design and development to products ready for production. The highest priority is placed on the customers and the desire to offer outstanding benefits. The Weber Group’s daily mission is to make the fascination of Weber, where competence and passion create fascinating ideas and extraordinary solutions, come true.
Ralf Brändlin, Group Leader IT-ERP, responsible for SAP and MES in the Weber Group
HYDRA has helped us, among other things, to create a consistent data base for our KPIs and will continue to accompany us in the direction of Industry 4.0. The digital factory is unthinkable without a wellfunctioning MES system.
In 2004, the Weber Group introduced the Manufacturing Execution System HYDRA of MPDV to make production planning more effective, to better charge production areas to capacity and to create a consistent data basis for KPIs and controlling. Since then, the plastics experts have been using a wide range of HYDRA modules in conjunction with a powerful interface to the SAP ERP system. The graphic detailed planning of all upcoming orders and operations with HYDRA Shop Floor Scheduling is the core of the MES installation at the Weber Group.
In the course of the year 2016, the Weber Group decided to switch to the current HYDRA release 8. This ensured, that applications in use, e. g. Tool & Resource Management, are enhanced by newly available functions. Furthermore, HYDRA 8 also provides new modules in the latest release, e. g. DNC & Configuration Data. The Weber Group has also planned a rollout of the HYDRA system in China.
The release change went smoothly after an excellent preparation and the professional coordination with MPDV. The actual changeover took place on a weekend and on Monday in the early shift, all employees at both plants in Germany and Poland could use the new HYDRA functions. The user interface of the software can be operated intuitively, so that short instructions were sufficient to familiarize users with the new system. The Weber Group employees in Poland even planned and implemented HYDRA 8 on their own.
A major reason for the swift and smooth change to HYDRA 8 was, that the Weber Group took on most of the required preparations. Thanks to the flexible service offered by MPDV, the Weber Group was able to decide which tasks they could handle by themselves and where the support of the MES experts would be useful. The Weber Group provided the infrastructure, configured the new HYDRA functions, tested the MES applications and carried out the actual Go Live in a leading role. MPDV was only significantly involved in the migration of the applications and data.The introduction of additional HYDRA functions, the connection to the SAP maintenance module and rollouts to further production areas are planned for the coming years. The introduction of the automatic detailed planning for the process and setup optimization using HYDRA Shop Floor Scheduling is also being considered.
- Windows server including MS SQL database
- Interface to SAP ERP
- Ca. 100 HYDRA office clients
- 70 HYDRA shop floor clients
- Connection to 135 injection molding machines of different manufacturers
- 25 integrated assembly and group workstations