FANAR improves its production processes with Asprova APS

 

Production automation is a direction in which the FANAR factory has been going for many years. This is related to the specifics of its industry – the production of cutting tools for metalworking – and the challenges that must be realised every day to perfectly match orders to the needs of customers. The high quality of its products requires the use of specialised machines that work without interruption in complex conditions. However, automation itself associated with the operation of machines is not enough to achieve success. At the same time, production management processes should be improved, especially in the area of planning and scheduling.

The FANAR company – aware of the challenges of its industry – decided to implement the Asprova APS system by our specialists. This brought a number of benefits regarding both the improvement of the production process itself and the improvement of work comfort.

System selected:
Asprova APS

Year of implementation:
2018

Areas:
production planning and scheduling

Number of operations in the production plan:
25 tys.

System selected:
Asprova APS

Year of implementation:
2018

Areas:
production planning and scheduling

Number of operations in the production plan:
25 tys.

In the first months of the implementation of Asprova APS we noticed the desired effects – we managed to reduce the maximum production times by half. After three months of using the system, the average production time was also reduced by half. However, we will continue to work on its optimisation by supplying production lines based on supermarkets. The system is necessary in their proper planning and automatic start of production. By keeping an eye on every order, Asprova APS does not allow to plan the implementation of subsequent production processes beyond the maximum occupancy of machines.

A big surprise, unexpected at the start of the implementation of Asprova APS, was also the improvement of logistics processes. Earlier, orders were created to describe a product by own or customer’s brand through Microsoft Excel once a month. It did not give satisfactory results and required a lot of work. We are currently creating dedicated technologies for this type of order in the system. Asprova APS generates hundreds of them every day, this number reaches 20,000 a year.

A significant challenge after the implementation of the system was the resistance from operators in the implementation of the Asprova APS schedule. Earlier, the order of orders on the work cell was determined by area managers, and operators had a large impact on this. Currently, we create a schedule centrally for the entire company in the system, taking into account more criteria than the operator sees. This caused some misunderstandings. The operators initially did not trust the schedules they received, but over time the situation cleared up. The effect of shortening production time was the biggest argument in the discussion.

Krzysztof Stanisławczuk, Operations Director

  • Purpose

    Automation of the creation of production orders. Improvement of timeliness of realisation of orders

    Effect

    Reduction of average and maximum production times by half. Reduction of the total times of machine changeovers and the release of 1.5 day jobs, which resulted in a reduction in employment costs. More efficient supply of warehouses. Increasing product availability in stock from 90% to 99%.

  • Purpose

    Increase in the efficiency of the entire production process

    Effect

    The ability to create many variants of the entire production process. Accurate determination of raw materials and semi-finished goods delivery times. Control of individual production stages. Planning of material needs, taking into account the required number of semi-finished products / products at the time when there is a demand.

  • Purpose

    Introduction of material balancing and benchmark technology with variants of realisation

    Effect

    Facilitating the high variability in creating the production process and selecting resources: machines, work cells or materials by automation of technology recording.

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