Success Story Video

KSB Digital Factory

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Harald Hofmann
Location manager and spokesman, Pegnitz plant, KSB

Digital connectivity is an important task for all areas of the company which lets us face many challenges. In order to successfully implement our initiatives, we decided for the support from STAUFEN.DIGITAL NEONEX. The partnership and professional cooperation impressed the whole management.

Martin Heier, Ingenieur Process Performance, KSB
Martin Heier
Ingenieur Process Performance

In just eight months, we built our pilot assembly cell in Pegnitz based on lean criteria and introduced paperless production including the Manufacturing Execution System and one-piece flow. That would not have been possible without the agile project method from NEONEX.

Project approach

The project Digital Factory @ KSB aims to realign the entire value creation process. Behind it is the desire to serve customers faster and more efficiently in the future. KSB started with the identification and analysis of a variety of use cases in a pilot plant. From the beginning, cross-departmental and cross-plant collaboration have been promoted in order to simplify the global roll out of use cases after the successful introduction in the pilot plant.

The particular challenge of the project lies in the simultaneous realignment of production and the desire for connected processes along the entire value stream (End2End). In addition to the use of modern, connected, digital solutions and the establishment of lean production and business processes, the essential components of the holistic approach are the necessary change and communication processes. The agile project management implemented by NEONEX as well as the monthly steering committees ensure a very quick, successful and pragmatic implementation.

The currently 10 use cases (including advanced planning, MES, digitally supported documentation process, ...), have been set up by defining the target processes in short design sprints with the employees. After a standardized selection process and successful implementation, support was also provided in the respective stabilisation and CIP phase and in the worldwide roll-out.

Benefits for KSB

Efficiency increase through waste-free processes
Higher customer satisfaction through faster and more reliable delivery times
Increased employee satisfaction

Horizontal connection of several use cases along the value stream

Implemented Use Cases

Digital applications

Digital solution: browser-based platform providing a structured process.
Digital solution: browser-based platform providing a structured process.
Use Case 1

Digital Supplier Documentation

  • Document Management
  • Workflow
  • Tracking & Tracing

Initial situation:
Manual collection of the required technical documents

Lack of transparency

regarding status, completeness, meeting deadlines of the documents

High manual effort

when searching for documents, handling the process, tracking and reviewing

Extensive communication

via different channels and with many loops due to the lack of information

Risk of delay penalties

and low delivery performance due to missing documents and long lead times


Digital solution:
Document management, workflow with tracking & tracing

Transparency

Complete overview of orders and the current document status.
All documentation requirements can be viewed in one place. All participants keep an overview of the scope of documentation, deadlines, releases, revisions etc. at all times.

Lean processes

Structure and automation save time and reduce throughput time.
The scope of documentation is structured according to order number and item and managed in a central location. This saves time-consuming communication via email. An automated test and revision process enables quick feedback and shorter processing times.

User friendly

Browser-based platform with the highest demands on comfort functions.
Simple operation, quick upload of documents via drag & drop from any device and at any time as well as intelligent functions inspire, simplify and accelerate the process.

Digital solution: Current visitor information on company and location via a digital info screen.
Digital solution: Current visitor information on company and location via a digital info screen.
Use Case 2

Digital Infoboard

  • Employee information
  • Standardized appearance for external visitors

Initial situation:
Paper-based information & offline presentations

Lack of topicality

of the information / KPIs on the group table for employees and internal visitors.

High manual effort

for maintaining the information internally as well as the data for visitors and seminar groups.

Lack of standardization

both within a plant and across plants.

Confusing and unstructured

no distinction between internal and external information.



Current and comfortable

All relevant information is immediately available on the touch screen.
News for external visitors can be updated across plants with one click.
Internal information and KPIs are visualized in real time from connected systems.

Individual despite standardization

A global standard creates the framework for plant-specific information.
A modular system enables the right information and KPIs to be visualized in the right place at the right time.

Increased external impact

Globally uniform presentation of the company and the services.
Modern and future-oriented reception of visitors with visitor-specific information at every company location ensures recognition and trust.

Digital solution: All logistics employees have mobile access to SAP warehouse management.
Digital solution: All logistics employees have mobile access to SAP warehouse management.
Use Case 3

Mobile Warehouse Management

  • Paperless intralogistics
  • Real time

Initial situation:
Manual, paper-based logistics processes

High manual effort

Logistics processes are controlled manually by paper-based transport orders.

High throughput times

Bookings can only be made at stationary terminals.

Error prone

Sorting and bracketing transport orders manually.

Limited responsiveness

Especially in the case of order changes or new prioritization.


Digital solution:
Mobile real-time information to control logistics

High responsiveness

All logistics employees have mobile access to SAP warehouse management.
Real-time information at any place and at any time increases the ability to react to unplanned changes.

Reduced lead time

Manual control processes are completely eliminated.
Transport order confirmations and correcting bookings can be carried out on site.

High transparency

All orders are booked in real time.
Rush orders can also be accelerated transparently via the system.

NEONEX service: Structured support through the selection process.
NEONEX service: Structured support through the selection process.
Use Case 4

MES Supplier Selection

  • MES
  • Supplier selection

Initial situation:
Lack of transparency regarding MES functionalities and providers

High number of providers

There are over 150 MES providers on the German market alone.

Diverse range of functions

The different range of functions of the MES providers is hard to understand.

MES or individual software?

Choosing between MES and individual software for special functions is challenging.

Unclear requirements

Many different interests in the company hinder a quick decision.


NEONEX service:
MES assessment and professional selection process

Clarity

About required MES functionalities.
With the help of the MES assessment, a uniform understanding of relevant MES functionalities was created and delimited from individual software.

The "right" provider

Selected on the basis of functional, commercial and infrastructural evaluation.
The structured selection process led to a clear team decision and a decision template for the steering committee.

Speed

Accelerated decision making through uniform understanding.
By specifying the identified use cases, the added value of an MES system became transparent for all those involved right from the start.

Digital solution: paperless one-piece flow assembly.
Digital solution: paperless one-piece flow assembly.
Use Case 5

Smart Assembly Line

  • Assembly
  • Assistance systems

Initial situation:
Paper-based batch production in assembly

Inefficient, push-driven processes

lead to unstable processes with high manual effort.

Long lead times

prevent the customer from being supplied faster.

High manual effort

both in assembly processes and in the event of deviations.

Lack of transparency

for continuous improvement.


Digital solution:
One-piece flow assembly with various assistance systems

Increased process stability

Through a smooth installation in one-piece flow with system support.
The worker is digitally supported by the correct information about the order and a pick-by-light during assembly.

Reduced lead time

Classic and digital waste has been discovered and eliminated.
Continuous process analyzes based on the collected data enable a data-based continuous improvement process.

Increased flexibility

Real-time information enables short-term reaction to changes.
The worker receives the right information at all times and reports back in real time in the MES system.

Reduced area

Thanks to a new, optimal layout, 1/3 of the space could be saved.
The sequence of activities has been optimized according to classic LEAN aspects.

Data Analytics

Data-supported risk assessment across the entire product portfolio. Analysis of the actual processing time and simulation of the target workplaces.
Data-supported risk assessment across the entire product portfolio. Analysis of the actual processing time and simulation of the target workplaces.
Use Case 6

Data-supported assembly redesign

  • Assembly
  • Value Stream Design
  • Data Analytics

Initial question:
Which assembly concept offers the best solution in terms of efficiency and scalability?

Extreme variant production

Daily fluctuating order load for different product families.

Lack of transparency

regarding the efficiency of the assembly processes.

Workshop production vs. Line production

Can the currently prevailing workshop production be converted into line production?


Digital solution:
Data-based analysis as a basis for restructuring

Risk assessment as the basis for choosing the right manufacturing process.

Transparency about the daily demand peaks and the moving average over the daily processing time for a whole business year.

Workspace dimensioning based on the entire product portfolio.

Simulation of workplace capacity vs. the order volume. Ad-hoc analyzes can be carried out very comfortably and the dimensioning of the workplaces according to different criteria - series, size, material number etc. - can be simulated for the entire portfolio.

Uniform understanding from employee to managing director.

Transparency regarding the initial situation and potential for improvement. The visually prepared data make it possible to get all employees on board and to work together to develop potential improvements based on data.