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OPENMATICS

Process Management Success Story

Performance motorsports component manufacturer took steps towards Industry 4.0 using OPENMATICS Asset Tracking solution for Process Management. OPENMATICS provided a flexible digital solution for production monitoring to improve production accuracy and efficiency for ZF Race Engineering, high-performance motorsport specialist.

Performance motorsports component manufacturer took steps towards Industry 4.0 using OPENMATICS Asset Tracking solution for Process Management. OPENMATICS provided a flexible digital solution for production monitoring to improve production accuracy and efficiency for ZF Race Engineering, high-performance motorsport specialist.

OUR CLIENT: A LEADING EXPERT IN HIGH-TECH MOTORSPORTS ENGINEERING SERVICES

ZF Race Engineering provides complete engineering services related to the development, production and distribution of high-performance, high-precision motorsports components – shock absorbers, clutches, transmissions and as well as additional ZF products for all kinds of worldwide motorsports applications.

Top racing categories around the globe from Formula 1, World Rally Championship, DTM and the 24h of Le Mans to the innovative, all-electric Formula E rely on high-tech products from ZF..

CHALLENGES FACED

The market is demanding more and more flexibility and shorter reaction times. To keep success on a high level ZF Race Engineering decided to bring their production and planning processes into the digital age and make them ready for Industry 4.0.

Three use cases were identified as most in need of overhaul – Production Planning, Production Monitoring and Worker Assistance. The OPENMATICS deTAGtive solution was chosen to digitise Production Monitoring.

Before OPENMATICS solution was implemented, ZF Race Engineering was primarily using non-digital methods of order and process management. Paper orders were printed and collected before being manually assigned to workers or different workplaces.. he system was not flexible, , intransparent and not userfriendly for the employees..Daily changes were difficult to reproduce and orders could not be localized directly in the process flow.

OUR CLIENT: A LEADING EXPERT IN HIGH-TECH MOTORSPORTS ENGINEERING SERVICES

ZF Race Engineering provides complete engineering services related to the development, production and distribution of high-performance, high-precision motorsports components – shock absorbers, clutches, transmissions and as well as additional ZF products for all kinds of worldwide motorsports applications.

Top racing categories around the globe from Formula 1, World Rally Championship, DTM and the 24h of Le Mans to the innovative, all-electric Formula E rely on high-tech products from ZF..

CHALLENGES FACED

The market is demanding more and more flexibility and shorter reaction times. To keep success on a high level ZF Race Engineering decided to bring their production and planning processes into the digital age and make them ready for Industry 4.0.

Three use cases were identified as most in need of overhaul – Production Planning, Production Monitoring and Worker Assistance. The OPENMATICS deTAGtive solution was chosen to digitise Production Monitoring.

Before OPENMATICS solution was implemented, ZF Race Engineering was primarily using non-digital methods of order and process management. Paper orders were printed and collected before being manually assigned to workers or different workplaces.. he system was not flexible, , intransparent and not userfriendly for the employees..Daily changes were difficult to reproduce and orders could not be localized directly in the process flow.

BLUETOOTH TAG SYSTEM PROVIDES COMPLETE PROCESS MONITORING TRANSPARENCY

TAG finders were installed at key stations of the manufacturing facility. Once client orders are prepped for manufacturing, a single Bluetooth TAG is associated with that order. All the information and necessary manufacturing steps are connected to that TAG. ZF Race Engineering get a clear picture of the workflow, with information on how long the order takes to pass through each process step.

Staff members can see which orders and tasks have been assigned to them as this data is displayed prominently in the facility and automatically updated. The Process Monitoring solution also integrates with ZF Race Engineering’s Worker Assistance system, tracking which assembly steps have been confirmed for each order...

BLUETOOTH TAG SYSTEM PROVIDES COMPLETE PROCESS MONITORING TRANSPARENCY

TAG finders were installed at key stations of the manufacturing facility. Once client orders are prepped for manufacturing, a single Bluetooth TAG is associated with that order. All the information and necessary manufacturing steps are connected to that TAG. ZF Race Engineering get a clear picture of the workflow, with information on how long the order takes to pass through each process step.

Staff members can see which orders and tasks have been assigned to them as this data is displayed prominently in the facility and automatically updated. The Process Monitoring solution also integrates with ZF Race Engineering’s Worker Assistance system, tracking which assembly steps have been confirmed for each order...

The user-friendly deTAGtive portal allows fast and easy reassignment of tasks, changes in prioritisation and grouping orders according to different criteria e.g. high priority orders or orders requiring the same tooling. Most importantly, the entire manufacturing process and process monitoring system is transparent, providing several key performance indicators directly out of the box e.g. bottle necks and average cycle times for each process.

Our client could now:

  • Define their own process stations in relation to real maps of their manufacturing facilities
  • Connect one Bluetooth TAG to each individual job and assign it to assembly production lines for different tasks
  • Keep a transparent historical record of all actions and movements associated with each job
  • Accurately track lead times, work in progress and production efficiency

OPENMATICS worked closely with ZF Race Engineering during implementation of the Process Tracking solution, listening to their needs and requirements to develop useful new deTAGtive features. The result – a solution truly optimised for the shopfloor.

WHY THE OPENMATICS SOLUTION?

RFID was considered as a solution, however the Bluetooth TAG system was considered more convenient, cost-effective and user-friendly. In addition, the flexibility, transparency and customisation options of the deTAGtive portal made OPENMATICS the best option.

The user-friendly deTAGtive portal allows fast and easy reassignment of tasks, changes in prioritisation and grouping orders according to different criteria e.g. high priority orders or orders requiring the same tooling. Most importantly, the entire manufacturing process and process monitoring system is transparent, providing several key performance indicators directly out of the box e.g. bottle necks and average cycle times for each process.

Our client could now:

  • Define their own process stations in relation to real maps of their manufacturing facilities
  • Connect one Bluetooth TAG to each individual job and assign it to assembly production lines for different tasks
  • Keep a transparent historical record of all actions and movements associated with each job
  • Accurately track lead times, work in progress and production efficiency

OPENMATICS worked closely with ZF Race Engineering during implementation of the Process Tracking solution, listening to their needs and requirements to develop useful new deTAGtive features. The result – a solution truly optimised for the shopfloor.

WHY THE OPENMATICS SOLUTION?

RFID was considered as a solution, however the Bluetooth TAG system was considered more convenient, cost-effective and user-friendly. In addition, the flexibility, transparency and customisation options of the deTAGtive portal made OPENMATICS the best option.