KOLEKTOR Sikom, a company with discrete production operations, 700 employees, and an annual revenue of 100 mil EUR, faced significant challenges in their production processes. Integrated with SAP and Sinapro (MES), KOLEKTOR Sikom’s existing system was not enough to handle the dynamic nature of their production needs.
The primary challenge was the time lost in manually creating and uploading the production plan and schedule. This process was not only time-consuming but also prone to errors. Additionally, fine-tuning the schedule via phone and email further added to the inefficiencies. Knowledge about the production plan was often locked within the planner and team coordinator, making it difficult for others to step in and make informed decisions when needed.
Gregor Jereb, a planner at KOLEKTOR Sikom, highlighted a significant pain point: “I spent 2 hours per day gathering and combining information from three different IT systems and phone calls to conceive a micro plan and to prepare my team for the next work order.” This manual process led to longer downtimes and slower responses to unplanned events, impacting overall productivity.
In the fast-paced world of automotive manufacturing, efficient production planning is critical.
Implementing solutions for better production planning
To tackle these challenges, KOLEKTOR Sikom needed a robust solution to streamline their production planning and reduce manual intervention. The integration of advanced production planning tools became a game-changer for the company. By leveraging these tools, KOLEKTOR Sikom automated the creation and uploading of production plans, significantly reducing the time spent on these tasks.
One of the critical features implemented was the synchronization of information across SAP and Sinapro (MES). This integration ensured that all relevant data was available in real time, eliminating the need for planners like Gregor to gather information manually from multiple sources. As a result, the time required for planning and preparation was drastically reduced, allowing the team to focus on more strategic tasks.
Moreover, the new system enabled better communication and collaboration among team members. With automated updates and a centralized platform, everyone involved in the production process had access to the same information, reducing the reliance on individual knowledge and expertise. This change not only improved efficiency but also ensured that production could continue smoothly even in the absence of key personnel.
Additionally, the implementation of predictive analytics helped KOLEKTOR Sikom anticipate and respond to unplanned events more swiftly. By analyzing historical data and current trends, the system provided insights that allowed for proactive adjustments to the production schedule. This capability reduced downtimes and enhanced the overall responsiveness of the production team.
To wrap up
The case of KOLEKTOR Sikom underscores the importance of efficient production planning in the manufacturing sector. By addressing the challenges of manual processes and improving information flow, the company was able to enhance its production efficiency and reduce downtimes. The integration of advanced production planning tools not only streamlined operations but also empowered the team to make informed decisions quickly.
For companies facing similar challenges, investing in robust production planning solutions can lead to significant improvements in productivity and operational efficiency. As demonstrated by KOLEKTOR Sikom, the benefits of such investments extend beyond time savings, contributing to a more agile and resilient manufacturing process.