The pelzGROUP is made up of four dynamic and innovative single companies. More than 750 employees at the Wahlstedt location in Germany make sure today that the requirements of the customers can be fulfilled tomorrow. Willy Pelz founded in 1948 the company that initially produced cotton wool for dressings and cosmetics in Wahlstedt. Today, the pelzGROUP produces high-quality articles for beauty and body care on modern and fully automated production lines. For example, cotton pads, cotton swabs and many different products for the feminine hygiene or incontinence market. A special feature is the strong value chain of the pelzGROUP. Innovative technologies and know-how make it possible for the pelzGROUP to react to the customer requirements quickly.
Tim Hamann, Head of Production Optimization
In order to pinpoint all the improvements and potentials, we have set up a lean project for our employees to identify with. ”move” stands for motivation, organization, improvements and efficiency. MES HYDRA is the essential tool for this project.
In order to automate data collection in the shop floor, the pelzGROUP decided to introduce a Manufacturing Execution System (MES) in 2014 and started a quest for suppliers. The wide range of standard functions and the scalability of the offered system led to the decision in favor of the MES HYDRA from MPDV in 2015. The company also obtained information from other HYDRA users, who were highly satisfied with the MES.
In a first project phase, the HYDRA modules Shop Floor Data (BDE) and Machine Data (MDE) were introduced in order to replace the paper- based time tickets and at the same time to get the recorded data into the system more quickly and reliably. 3 to 4 orders are processed per day and machine, producing an average of 50,000 packaging units. A HYDRA shop floor terminal attached directly to the machine supports the operators at work. Even though printed documents can still be seen in production, all employees benefit from the fact that HYDRA always has an up-to-date data status and that the ERP system, developed in-house, is always well informed on all matters on the shop floor. In parallel, key figures such as OEE (Overall Equipment Effectiveness) can be calculated reliably at the touch of a button. A terminal was specially developed and patented in-house to connect the machines, while at the same time allowing an easy data input for the operators.
In a second phase, HYDRA functions for Time & Attendance (PZE) and Personnel Time Management (PZW) were integrated, which reduced the volume of paper to zero at least when applying for leave. These HR functions also form the basis for Personnel Scheduling with HYDRA PEP. In addition to the shift and year models stored in HYDRA, the qualifications of the production employees are also factored in. That simplifies the personnel management in production. The Access Control (ZKS) integrated in HYDRA guarantees that only authorized employees can enter the company premises as well as critical areas in production. To do this, HYDRA ZKS uses the same HR master data as all other HR functions in HYDRA.
In another project, pelzGROUP would like to introduce the digital documentation of tools which in turn supports the allocation of multi-part tools. The monitoring of maintenance cycles is also part of this function extension. Both piece lists and the identification of tools by QR code and the transfer of logged resources to the next work step belong to the challenge that will be solved with HYDRA WRM (Tool & Resource Management) in the future. Currently the pelzGROUP uses the integrated maintenance calendar for the strict compliance of inspection cycles for hoists and ladders.
Furthermore, the pelzGROUP MES team is currently examining the applicability of the HYDRA Energy Management (EMG) as well as the functions for an integrated quality assurance.
- Windows server with MS SQL database
- Interface to CDIX (self-developed ERP system)
- ca. 100 HYDRA office clients
- ca. 20 HYDRA shop floor clients