The FactoryDirector data management system makes all production, article and technology information available digitally on InfoPoints in production. This has enabled Zollern to reduce set-up and non-productive times in some areas by around 20 percent. © Customs

Furthermore, when introducing a new system, the aim was to cover the individual requirements of the Zollern plant in Braunschweig on the one hand and to use standard software on the other. Künze puts it this way: "Customized software always leads to a one-way street due to its problematic updatability. The Coscom software is an expandable, future-proof system based on the Lego principle: 'Make ONE system into MY system', without leaving the standard. All in all, Coscom was the ideal partner here, as the software specialists developed a master plan for the rollout in consultation with us, took over the project management and accompanied the introduction step by step with their production expertise. We needed a partner who could support us not only with the software, but also with their experience in project management." The new Coscom solution offers the Zollern plant a wide range of options and can be expanded as required to meet future requirements - both within the plant and across plants.

Using experience from the learning workshop for the rollout

In order to test the acceptance of the new system and to integrate it into production as quickly and optimally as possible, it was initially introduced in a training workshop. The advantage: experience could be gained in a sub-area of production and employees could be sensitized and motivated to ensure acceptance of the new system. The learning workshop was also about using discipline to create a binding set of rules. With this experience, the ToolDirector and FactoryDirector infrastructure software could be rolled out step by step. The departmental introduction of the system also had the advantage of arousing interest among the workforce.

At the beginning of the introduction, the project team also had to consider how to keep the new knowledge clean so that only truly relevant information is included in the database. "The other magic word is 'discipline'," explains Production Manager Oschmann. "The employees have to adhere to the defined rules at all costs, for example, only information that deviates from the standard is entered in the 'Comments' field, everything else stays out." It was also important that new information reaches employees as quickly as possible so that they can use this knowledge promptly and profitably in their work. To get this information into the system as quickly as possible, all employees have to actively contribute. Getting the workforce to fill the database with relevant information on the one hand and to use this information on the other was one of the biggest challenges for the production manager when introducing the system.

Clean data through key users

The Braunschweig plant produces plain bearings for compressors, diesel engines and bearing sets. The Coscom software enables efficient and value-adding production of the components. © Customs

The introduction of the new production information system at Zollern was accompanied by the issue of a "clean database". Künze explains: "If, for example, three employees work in three shifts on one machine, up to six different NC programs can be stored in the database for the same product. Of course, all six are suitable for the production of this part, but which one is the best economically or technically? The solution: An experienced key user ensures that the database remains clean and that only the most suitable program is activated. Today, experienced employees in particular are more and more 'process designers' than mere machine operators. It is their job to ensure that the data is clean and correct." In order to keep the systems free of less or irrelevant information, the key users act as guardians of the databases, so to speak. Thanks to their experience and knowledge, they can assess the value of the information and sensitize and train their colleagues so that they only store information that is really important.

In addition to the Tool and Factory Director production databases, Oschmann and his team also introduced so-called digital InfoPoints in production. These are PC terminals on which the employees not only receive all the information from the Coscom knowledge database, but can also call up further information about the company and their work.

In addition to SAP data, they also have access to the company's key figures. "We want to make this information transparently accessible to all employees, regardless of whether they work day or night shifts, so that they are aware of what is happening at the plant and in the company as a whole. Here too, our motto is: less paper through digital online information," says Oschmann. For Zollern, these InfoPoints serve as extended communication channels. They provide this data to the right process participant at the right time and in the right place as required.

Central tool stores guarantee an overview of tools. The ToolDirector manages all individual components and complete tools digitally. © Customs

Work preparation has also been integrated. The Tool and FactoryDirector is now available to the AV employees as a communication and data hub, as all the information required for the production of a specific part can be stored and accessed there. Künze describes the benefits as follows: "You don't need to know it. You just need to know where it is! The added value of the system is demonstrated on a daily basis, particularly in the production of repeat parts and as part of change management. The employees also enter all further information that is important for the production of this part. This information is then incorporated into the subsequent process standard and the entire CIP process. With the system, we digitize and secure the entire production know-how."

Reduce set-up and non-productive times

Other positive results were also evident, as Künze states: "We very quickly noticed that we were able to reduce set-up and non-productive times by 20 percent in some areas." There were also further improvements in the production process. Instead of decentralized tool storage at the machines, the introduction of Coscom led to the establishment of a central tool warehouse. The ToolDirector warehouse application informs employees about the areas and locations where all tools are used in production: Are they in use? If so, where? Are they defective? Are they available? The right individual and complete tools also reach the right place more quickly.

The system has also shortened the start-up phases when commissioning new machines. Whereas it used to take up to two months for a new machine to be ready for use, it now only takes just under two weeks. "Even before a new machine was introduced, Coscom enabled us to guarantee a reliable process design and thus significantly shorten the start-up phase, meaning we were able to bring the new machine into production with time and capacity gains," recalls Künze.

The ToolDirector warehouse application informs employees about the storage location and quantity of all tools in production. © Customs

In addition, the employees were able to work more flexibly, as the necessary data, programs and information were available to them for the new machine right from the start. This made it possible to complete tasks on the new machine faster, more flexibly and, above all, with greater safety.

Centralized knowledge secures jobs
Oschmann is satisfied with the decision to opt for Coscom, and the qualitative successes speak for themselves: "The willingness to share knowledge has increased enormously among the workforce. The system also helps to secure jobs because every single employee becomes more flexible thanks to this centrally available knowledge. This means that even if there are optimizations at a workplace, the necessary information is available immediately." Künze: "The Coscom system is at the heart of our transformation into the digital age, combining interpersonal aspects with the economic goals of streamlining and optimization as part of digitalization."