ZF Aftermarket Worldwide -

Your Partner Wherever You Are

You are here:

If your Country is not listed, select "Other countries" to visit our ZF Aftermarket Global website.

All ZF Aftermarket websites

Find your region

You are looking for company information on ZF Friedrichshafen AG?

Visit our corporate website

Please select your region and language:

Back
Asia
Europe
Latin America
Middle East
North America
Oceania
South Africa

Couldn't find your region and language? Visit our Global website: English

Note

The page you are navigating to is not optimized for mobile devices.
Do you want to proceed?

Proceed
EN
Contact

Global

Global

Process Management Success Story

Performance motorsports component manufacturer took steps towards Industry 4.0 using ZF OPENMATICS Asset Tracking solution for Process Management. ZF 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 ZF OPENMATICS Asset Tracking solution for Process Management. ZF 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 ZF OPENMATICS deTAGtive solution was chosen to digitise Production Monitoring.

Before ZF 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. The 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 ZF OPENMATICS deTAGtive solution was chosen to digitise Production Monitoring.

Before ZF 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. The 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

ZF 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 ZF 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 ZF 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

ZF 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 ZF 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 ZF OPENMATICS the best option.

Privacy Preference Center

Your Privacy

When you visit any web site, it may store or retrieve information on your browser, mostly in the form of cookies. This information might be about you, your preferences, your device or used to make the site work as you expect it to. The information does not usually identify you directly, but it can give you a more personalized web experience. You can choose not to allow some types of cookies. Click on the different category headings to find out more and change our default settings. However, you should know that blocking some types of cookies may impact your experience on the site and the services we are able to offer.

Technical Mandatory Cookies

These cookies are necessary for the website to function and cannot be switched off in our systems. They are usually only set in response to actions made by you which amount to a request for services, such as setting your privacy preferences, logging in or filling in forms. You can set your browser to block or alert you about these cookies, but some parts of the site will not then work. These cookies do not store any personally identifiable information.

Analytics Cookies

These cookies allow us to count visits and traffic sources so we can measure and improve the performance of our site. They help us to know which pages are the most and least popular and see how visitors move around the site. All information these cookies collect is aggregated and therefore anonymous. If you do not allow these cookies we will not know when you have visited our site, and will not be able to monitor its performance.

More Information

Your Privacy

When you visit any web site, it may store or retrieve information on your browser, mostly in the form of cookies. This information might be about you, your preferences, your device or used to make the site work as you expect it to. The information does not usually identify you directly, but it can give you a more personalized web experience. You can choose not to allow some types of cookies. Click on the different category headings to find out more and change our default settings. However, you should know that blocking some types of cookies may impact your experience on the site and the services we are able to offer.

Technical Mandatory Cookies

These cookies are necessary for the website to function and cannot be switched off in our systems. They are usually only set in response to actions made by you which amount to a request for services, such as setting your privacy preferences, logging in or filling in forms. You can set your browser to block or alert you about these cookies, but some parts of the site will not then work. These cookies do not store any personally identifiable information.

Analytics Cookies

These cookies allow us to count visits and traffic sources so we can measure and improve the performance of our site. They help us to know which pages are the most and least popular and see how visitors move around the site. All information these cookies collect is aggregated and therefore anonymous. If you do not allow these cookies we will not know when you have visited our site, and will not be able to monitor its performance.