As a family-run business acting globally, with over 9,300 highly qualified employees, the WIKA group of companies is a worldwide leader in pressure and temperature measurement. The company also sets the standard in the measurement of level, force, flow, in calibration technology and SF6 gas solutions. Founded in 1946, WIKA is today a strong and reliable partner for all the requirements of industrial measurement technology, thanks to a broad portfolio of high-precision instruments and comprehensive services.
With manufacturing locations around the globe, WIKA ensures flexibility and the highest delivery performance. Every year, over 50 million quality products, both standard and customer-specific solutions, are delivered in batches of 1 to over 10,000 units. With numerous wholly-owned subsidiaries and partners, WIKA competently and reliably supports its customers worldwide.
Dr. Alexander Nachtwey, Head of Chipping at WIKA
Due to HYDRA we could improve our planning processes significantly. In the Shop Floor Scheduling module, our production planners and group leaders can instantly see where backlogs are due to occur and can intervene immidiately. Since the introduction of the MES system, our delivery reliability has improved from 80 to 95%. Using the MES system in the tool shop management has also led to an increase in productivity by about 5%.
In WIKA’s pre-fabrication, a variety of high-precision metal parts are machined and fed to the assembly. WIKA decided to introduce a Manufacturing Execution System upon the advice of a lean consultant and in order to remain efficient and productive in spite of the rising product variety. The main reason selecting the MES solution HYDRA by MPDV was its broad range of standardized modules to cope with different tasks. But also the mindset of the MES experts from MPDV suited WIKA. The close vicinity of MPDV and the international experience was also appreciated. Furthermore, WIKA expected from the introduction of the MES system the opportunity to optimize production control and to standardize controlling and reporting.
Collecting reliable order and machine data benefits production control that can improve their planning due to reliable data so delays in production can be more than compensated. While planning orders, availability of NC programs and setup sheets is also checked. The color of the planned order (bar) informs about the time lag to the basic dates which are carried over from the leading ERP system (Microsoft Dynamics AX). Therefore, planners can always see the time available to complete the order.
Additional HYDRA modules for Tool & Resource Management and DNC & Configuration Data facilitate preparation procedures in the finishing shop or pre-fabrication. Due to time allowances provided by detailed planning, staff working in the tool store are informed, which tools are required next and can prepare these. Short-term re-planning can also be conducted smoothly. Integration of quality management with the modules for In-Production Inspection and Test Equipment Management enables to set inspections according to the different working steps. Outstanding inspections are also directly signaled on the shop floor terminal. This enables a straightforward operator self inspection directly at the machine and if necessary, these inspections are supported by more elaborate analyses from the quality lab. Due to a uniform user interface of the HYDRA Shop Floor Client, production staff only have to learn how to operate one system. In using HYDRA, WIKA could significantly increase their delivery reliability and productivity.
The introduction of HYDRA in 2011 took approx. 6 months, including the training of key users. At the beginning of 2013, WIKA switched successfully to the current HYDRA 8 version. In the following years, the existing HYDRA solution was rolled out to further sites in Germany, Poland and the USA.
- Windows Server with Microsoft SQL data base
- Interface to Microsoft Dynamics AX (ERP)
- Approx. 40 HYDRA Shop Floor Clients
- Approx. 30 HYDRA Office Clients
- Approx. 80 machines connected (incl. DNC)