references | 09.06.2021

Sohbi Craft Poland develops with the Asprova APS system

Sohbi Craft Poland is a company with Japanese capital, which does not need to be introduced on the domestic land, and which is not less successful in Poland. Gaining the trust of a Japanese company and establishing cooperation is a success of the eq system. As a result, Japanese production technology met Japanese information technology supporting production management and the APS Asprova system was implemented in Sohbi Craft Poland. The effects of the implementation allow us to look to the future with optimism and to expect further, dynamic development of the company. Read what Sohbi Craft Poland has gained after one year from the start of the implementation of the Asprova APS system. 

Sohbi Craft Poland – about the company 

Sohbi Craft Poland has been operating since 2006. The company’s new business is the production of FFP2 respirators, but the main area of activity is the production of pressed metal elements for the automotive industry. Engine brackets, elements of the steering system, airbags, seats, air conditioning, batteries… These are parts manufactured by Sohbi. Except for pressing, what is also done is threading, riveting and welding. 

Above mentioned products are delivered to almost all countries of the European Union. The company can also boast about cooperation with enterprises from Mexico and the USA. The scale of activities is reflected in the size of the company – Sohbi currently employs 250 people, working in the plant with an area of 11,000 m2. 

Production process in Sohbi 

The production process at Sohbi Craft Poland certainly required organising and optimisation, although it was apparently not complicated. It was found that the level of raw materials inventory is unsatisfactory, and its value is as much as 67% of the value of the finished goods inventory. In turn, the value of work in progress represented 8% of the value of the inventory of finished products, which also required improvement. Due to contracts with customers, the company must maintain the safety stock in the finished goods warehouse at set levels. 

Eq system experts, during meetings with company representatives, also diagnosed that Sohbi wastes 1080 minutes a day for changeovers. It turned out that creating a correct and effective production plan in a situation where employees work in a 3-shift system, 5 days a week, is a big challenge, all the more so because they wasted 60% of the time on the daily review of materials, obtaining information and creating a production plan that was just a few days ahead. The implementation of the eq production control standard, based in this case on the APS Asprova system turned out to be the solution. Such tasks were given as: 

  • Reduction in inventory and WIP 
  • Reduction of the number of changeovers 
  • Scheduling based on a precise production plan, not on variable forecasts 
  • Shortening the planning time and expenditure on its creation 
  • Creating long-term planning opportunities. 

Have we succeeded? 

The APS Asprova system – how does it improve work at Sohbi? 

The APS Asprova system uses real-time data because it has been integrated with the warehouse management system (thanks to which it always takes into account the current inventory status) as well as with the customer order system and production progress. In Asprova, changeover times, production standards and schedules are also planned, taking into account e.g. availability of employees and other process limitations. The planner no longer wastes time on creating a production plan in Excel, which will have to be modified anyway – now his main function is to optimise the schedule and take into account new optimisation criteria. This is perfectly illustrated by the numbers. The APS Asprova system implemented in Sohbi Craft Poland made the time of collecting data and its analysis shorter by 50%. The plan preparation time, in turn, is reduced by 60%, and the number of changeovers has been reduced by 40%. 

Before the implementation of the Asprova system in the company, it was not possible to deal with process improvement. Now, the time saved is spent on improving the company’s operational strategy as well as on decision making and analytical activities. Other tasks, according to defined rules and optimisation criteria, are automatically performed by Asprova. 

A noticeable benefit of implementing Asprova is also the increased planning horizon: from a few days to 6 months. The production plan is no longer a surprise to anyone. 

What else will the APS Asprova system change? 

After 12 months from the start of the APS Asprova implementation, Sohbi can change its planning strategy from reactive to preventive. The improvement of production planning also gives an opportunity to further optimise logistics processes and reduce the level of raw materials inventory from 67% to 38% in relation to the value of the finished goods inventory. The above assumptions, as well as the reduction of the value of production in progress from 8% to 2% in relation to the value of the inventory of finished goods, constitute Sohbi’s goal for 2021. It must work with Asprova. 

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