“The MDA (Machine Data Acquisition) module is our basic tool for determining losses in the area of packaging lines and,
therefore, is an essential tool for our production.“

Be it fix products, salad dressings, soups, sauces or ready-made meals: Unilever’s flagship brand “Knorr” is represented in more than 100 countries worldwide. In Germany alone, more than one billion “Knorr” packagings end up in shopping trolleys per annum.
The company was founded in 1838: Carl Heinrich Knorr opened his grocery store in Heilbronn. 150 years later, the name “Knorr” became synonymous with tasty and ready-made soups and paved the way for the convenience idea.
Since the beginning of 2013, the MES (Manufacturing Execution System) FASTEC 4 PRO has supported the production of the Unilever plant in Heilbronn.

“The MDA module is our basic tool for determining losses in the area of packaging lines and is therefore an essential tool for our production. Nevertheless – or perhaps because of that – we permanently have new ideas on functional extensions that requires a continuous collaboration with FASTEC. There are certainly more projects to come”.

Gerhard Weinert, Business Process Management Manufacturing, Unilever Deutschland Produktions GmbH & Co. OHG, factory Heilbronn

“With FASTEC 4 PRO, we have current performance, and therefore cost data, at any time.”

At Eisengiesserei Baumgarte, currently 230 employees work on a production surface of 20,000 m² in a highly modern production facility. Each year, about 30,000 tonnes of parts are cast and processed here.

For the Baumgarte iron foundry, one important step towards sustainability, performance capacity and the future was the introduction of a MES system. “With a MES system, we can react to changing market conditions more efficiently and realise our customers’ increasing requirements for our cast parts with consistent high quality. With the MES system we have current performance, and therefore cost data, at any time.”

Volker Spruch, Technical Controlling Manager and MES Project Leader, Eisengiesserei Baumgarte GmbH

“Having started in 2012 with two pilot installations in one of our fabrics and one of our rolls plants, FASTEC 4 PRO is now installed in 20 plants, across 4 regions, with more than 600 machines connected.“

Every plant now benefits from the powerful reporting capabilities, that provide all the needed information to the local staff. Additionally, all data is centralized in our global BI system to benchmark sites globally.

The savings we achieved with the help of the data provided by FASTEC are impressive: Throughout the whole FRS division, we could increase our OEE value by 10% within 2 ½ years. By reducing setup times and other types of LEAN-waste, we could reduce the planned machine time by an average of 3 hours per day, while keeping similar value added time.

The global rollout went smoothly and according to our schedule. The cooperation with you and your team was always very pleasant and professional.

Meanwhile, the OEE system is also being rolled out into other divisions of Voith, where we expect to reach approximately 1000 units across 50 plants in Voith. In FRS we have now moved on to the rollout of the next FASTEC 4 PRO module, an optimized MES (Manufacturing Execution System).

I want to thank you and the entire Fastec team very much for your work to date and look forward to the continued success of our future projects.”

Dr. Christian Preslmayr, Senior Vice President Global Operations/Purchasing/Operations Excellence/EBM, Member of the Board of Management Voith Paper Fabric & Roll Systems

“By using the FASTEC 4 PRO Scheduling tool we could reduce drastically the planning time for efficient production plan on the one hand, on the other hand now reliable information about specific delivery times are possible.”

The PrimaVera Naturkorn GmbH with headquarter in Upper Bavaria Mühldorf emerged in 1990 in a mill decommissioned in the 80’s, whose tradition goes back in the 15th century. These days, the SME employs 55 staff and turns over 35 million Euros a year. 800 products, which need to be produced partly in single batches, are manufactured here on eight different production lines spread over 30 machines and over 200 silos.

“By using the FASTEC 4 PRO Scheduling tool we could reduce drastically the planning time for efficient production plan on the one hand, on the other hand now reliable information about specific delivery times are possible. In addition, potential delays can be visualised straight away, which allows us to communicate more quickly with our customer and we could reduce our setup times and processing times.”

Sebastian Huber, Managing Director PrimaVera Naturkorn GmbH

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“The decision to install the FASTEC 4 PRO was spot on in our case. From first contact to commissioning of the system in our company took just 4 weeks.”

The decision to install the FASTEC 4 PRO was spot on in our case. From first contact to commissioning of the system in our company took just 4 weeks.

What was also impressive was that from the first day we captured meaningful data and could fully measure and keep track of our machines. This data helped us to undertake the first improvement steps. This system, although it is very powerful, is very intuitive to operate and simple to configure. At the same time it offers a wide range of possibilities and configurations so that it can be perfectly adapted to the customer-specific requirements of a company. Every change that we have made to the system, such as the automatic sending of reports, could be implemented by us within the shortest period of time.

In short we are impressed by the ease of operation, the user friendliness and the data quality that FASTEC 4 PRO offers us. Even now, after just a few weeks of use, we are sure that will install the system on more machines and will include more employees in working with the FASTEC 4 PRO.

So I can wholeheartedly recommend the FASTEC 4 PRO MES system.

Jan Stańczyk, proprietor of Radmot, Poland

Medice

“Already during the first month, thanks to easyOEE we could raise our OEE value on these three machines by up to 11 %.”

“Already during the first month, thanks to easyOEE we could raise our OEE value on these three machines by up to 11 %.”

In order to further expand and secure their international market position, this modern production facility in Iserlohn needed to be analysed for possible capacity reserves and optimised based on these results.

“We did not know which availability and performances our lines achieved. So we started with the productivity meter easyOEE to carry out a status-quo analysis on three machines in our assembly area. Thanks to easyOEE, we could raise our OEE value on these three machines by up to 11 % in the first month already. Based on this start, the MES system FASTEC 4 PRO was introduced and discovered additional capacity reserves, which lead to another 10 % increase in OEE during the first year it was used.”

Belal Al-Shaibani, Process Manager at MEDICE

Diehl_Metering

“We ultimately decided in favour of FASTEC because they could provide us with everything from a single source, which meant that we would be geared up for the future thanks to the available expansion options.”

By developing and manufacturing pioneering radio technology, Diehl Metering Systems GmbH makes an important contribution to the smart handling of water and heat. The innovative company produces 4.6 million radio modules a year in its Nuremberg plant.

To continue to be at the forefront of the competition was placed on the automatic detailed planning of the MES system FASTEC 4 PRO to optimize production. “We ultimately decided in favour of FASTEC because they could provide us with everything from a single source, which meant that we would be geared up for the future thanks to the available expansion options. Also, FASTEC 4 PRO allowed us to start with just the planning module and simply expand the system later on. And we obtained everything on one package without having to set up error-prone interfaces between systems frome different manufacturers.”

Alexander Seidel, Project Manager at Diehl Metering Systems

“After almost two years of use, I can acknowledge the major advantages offered by the acquisition of the FASTEC 4 PRO system.”

“After almost two years of use, I can acknowledge the major advantages offered by the acquisition of the FASTEC 4 PRO system. We purchased this system following a visit to a Bausch + Lomb site in Berlin.

I can now confirm that Fastec made efforts to adapt to our different needs.

We currently use FASTEC 4 PRO on 20 production lines at our Aubenas site, and we can no longer imagine working without it.”

Bouameur MOSTEFA, LEAN and Methods Engineer of Bausch + Lomb in Aubenas

“With easyOEE, we were able to achieve complete transparency.”

“With easyOEE, we were able to achieve complete transparency.”

“The large-scale solutions with intervention in the control were (…) too expensive (…) for us. At the start of this year we came across FASTEC, which convinced us with its simple easyOEE devices. (…) We (…) were able to achieve complete transparency.”

Jürgen Porsiel, Manager of Industrial Performance at Nestlé

“The deciding factor for FASTEC was its flexible connection concept that promised quick and cost-effective implementation”.

For over 30 years BARKU has been manufacturing high-quality plastic parts. The ever-evolving order situation led repeatedly to extreme difficulties in planning and scheduling. So the planning and production processes were to be visualized, analyzed and improved with the aid of an MES system. At the end of 2010, the company decided on the FASTEC 4 PRO modular MES system:

“The deciding factor for FASTEC was its flexible connection concept that promised quick and cost-effective implementation”.

“Before the introduction of FASTEC 4 PRO, we often had to produce at virtually 160 percent capacity. In 2012, we almost doubled our production rates in the extrusion plant. Thanks to FASTEC, in the planning department we managed to keep a good overall perspective.”

Sebastian Bähr, manager responsible for IT and Production at BARKU.

Westfalia Presstechnik, supplier for the automobile industry, uses easyOEE to optimise existing production processes.

Westfalia Presstechnik, supplier for the automobile industry, uses easyOEE to optimise existing production processes.

To see how quick and simple it was to set up easyOEE and to learn of the benefits it brought the company, have a look at this 3-minute video:

Click on the image to view the film (in German).

Isola

“We are delighted and are confident that we will be able to continue working with you in such an excellent manner even after now after the project phase.”

“We at ISOLA GmbH Düren wish to thank you and your colleagues for your collaboration with us in the past year.

Right from the very first negotiations with you, we knew that we had found a reliable partner for our OEE projects in FASTEC GmbH. Your goal is to be there for your project partners in a customer-oriented manner providing excellent support, and this you achieve completely. Certain circumstances meant that it was frequently necessary to change course during a project, and you showed flexibilityeven in these situations.

Service and support during the project phase are clearly emphasised in your company – you can tell that with every problem. Regardless of how big or small the problem was, ways and means were found to make the required system adaptations for as reasonable a price as possible.

We are delighted and are confident that we will be able to continue working with you in such an excellent manner even after now after the project phase.

Krieger, Production Manager, and T. Ermes, Lean Leader, Isola GmbH Düren

WKW

“The simple way of analyzing the figures convinced us to invest in easyOEE. Purchase this handy device, plug in a few cables, use the intranet-based web site for configuration and retrieve the data by pressing a button – easy, fast and universal.”

“The simple way of analyzing the figures convinced us to invest in easyOEE. Purchase this handy device, plug in a few cables, use the intranet-based web site for configuration and retrieve the data by pressing a button – easy, fast and universal. Furthermore, long downtimes are avoided via automatic e-mail alerts. The automatic calculation of the end time of the production orders also provides an ideal planning and communication solution – in real-time and worldwide!

We would like encourage FASTEC to modify the software for observation, analysis and optimization of production lines with multiple machines.” (editor’s note:. In Q2 2013 there will be an easyOEE client that allows monitoring multiple machines.)

Tobias Krause, Optimization, WKW automotive

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“We are very pleased. Around one year ago, our OEE values were only 35%, compared to the current 60%. Thanks to the increased transparency we have, we can now react in good time to malfunctions that occur in production, as well as being able to better plan our operations – stress is a thing of the past here.”

VION’s first experience of automatic data capture was with the immediately deployable productivity measuring unit easyOEE. They subsequently decided to upgrade to the MES system FASTEC 4 PRO:

“We are very pleased. Around one year ago, our OEE values were only 35%, compared to the current 60%. Thanks to the increased transparency we have, we can now react in good time to malfunctions that occur in production, as well as being able to better plan our operations – stress is a thing of the past here.

If anything unusual happens during the production process,we are able to react immediately and in a targeted manner. In addition, everything is recorded in detail and documented in a way that allows it to be analysed, which means that, through regular evaluations, we can achieve ongoing process optimisation.”

Dirk Kirchner, Production Manager at VION Convenience GmbH

Sartorius Stedim Plastics has seen someclear advantages through using the MES system FASTEC 4 PRO:

  • Increased productivity
  • Alarm systemwith escalation management
  • Reduction in errorsthrough automation of the previously error-prone label printing system
  • Automatic entryof stocks to the PPS system
  • Very quick acceptanceby the machine operators

“Since the MES-measures were introduced in March, we could increase the productivity of all our machines by up to 40 %.”

“Now these devices are installed on seven form presses and in one press line with five machines. Since these measures were introduced in March, we could increase the productivity of all our machines by up to 40 %. Which percent of this improvement is due to the data collection devices cannot really be answered. But there is no doubt that just through time monitoring, the utilised production times have risen by up to 10-15 %.”

Jürgen Lohmann, Production Manager Sofedit, ThyssenKrupp Umformtechnik GmbH

“With the introduction of easyOEE, we have been able to make the production process transparent.”

With the introduction of easyOEE, we have been able to make the production process transparent. It was important that the employees did not interpret this desire for transparency as a way of “monitoring” them but instead that they realise quickly that analysis of the reasons behind malfunctions is necessary before corrective action can be taken.

OEE evaluations and analyses of reasons behind malfunctions are regularly made available for discussion to the system and maintenance employees as well as to foremen. In one of the three systems equipped with easyOEE, this leads to an OEE increase of around 4 – 6 % and corresponds to a pay off period of only a few weeks.”

André Nikolaus, Head of Automotive Operations Scheduling,
SAMAG Saalfelder Werkzeugmaschinen GmbH, Saalfeld
November 2010

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“With easyOEE Portable GSM, we have found just the right system to evaluate and optimise our different machines.”

“With easyOEE Portable GSM, we have found just the right system to evaluate and optimise our different machines.

By now, we are also using it externally to gather first-rate datafrom companies with which we have good relations.

What we really like about the device are the unlikely high-performance configuration options. easyOEE can therefore bevery easily programmed for a wide variety of situations.”

Torsten Schlegel, CIP Coordinator, Alfred Ritter GmbH & Co. KG

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“With the now effective monitoring of the production processes that we have in place, we can detect errors and malfunctionsconsiderably better and earlier than before. We are able to counteract unplanned downtimes in a targeted manner.”

“In addition, we how have precise planning times at our disposal too. In this respect, we are see seeing significantly more transparency and flexibility as well as an increase in productivity. Against this backdrop of having ‘a living, expandable system’ for effective productivity increase at our disposal, we are looking forward with confidence to the future.”

Kai-Uwe Harms, Head of Manufacturing, Packaging Technology and Visual Controls athameln pharmaceuticals GmbH

“In February 2009, we decided to rent the easyOEE Portable system for three months. After just two days, the device arrived by post and I was able to put it into operation.”

The start-up was easy and went very quickly and smoothly. Within two weeks, we were able to optimise the configuration of the device and adapt it to meet the conditions on the line. The support staff at FASTEC were there to provide fast, professional help throughout this time.

Even during this early phase, we were able to see that we could drastically and immediatelyreduce the production losses on the line (which previously manifested themselves in the form of brief interruptions).

Over the course of the next few weeks, easyOEE became an indispensable tool, so much so that we can now say that the rental option was a complete success for us.”

Paul May, Metsä Tissue GmbH, Kreuzau

“I have collected the following statements from employees who have been working with the easyOEE system on our pilot line since May 2008”

  • Short period of adjustment and intuitive, simple operation
  • Concentrates on what’s important
  • Clarity
  • Flexible, customer-focused use
  • Good visualisation options and modes of evaluation
    to support processes of improvement
  • The option to enter free text for malfunction causes not stored
  • Option to correct data
  • Excellent service from FASTEC
  • Real-time data capture versus retrospect
  • All these advantages have, almost entirely of their own doing, together with having the right team in place, led to an improvement of 10% in the OEE on this line and have persuaded us to equip more production lines with the easyOEE system.”Dr. Holger Schoen, Environmental & Lean Management, Bausch & Lomb, Berlin
Logo_SanderGourmet

“We have ascertained that new formulations resulting from our development process or adjustments to existing formulations can be incorporated very easily. Only two or three runs are required and the formulation is ready.”

Extract from user report and technical article:

“We produce up to 8 tonnes of food every day using FASTEC-controlled systems. This equals roughly 22,000 meals. The way the system has simplified our work means that we never want to be without it. (…)

The consistent product quality desired is achieved without any problem. The initial scepticism of the employees abated very quickly after theimpressive results became clear and after their motivation grew as a result of the somehowmore relaxed working environment brought about by the system’s introduction.

Ewald Haupt, Head Chef at the “Cook and Chill” department at Sander Gourmet

“We have ascertained that new formulations resulting from our development process or adjustments to existing formulations can be incorporated very easily. Only two or three runs are required and the formulation is ready.”

Sven Lüttgens, Head of Production Planning at Sander Gourmet

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“Since easyOEE was introduced, the evaluations required are available in a timely mannerin electronic form, which means we can react faster to any problems that may arise.”

“Before we introduced easyOEE, our employees had to frequently make paper notes. The values obtained in this way were then transferred into Excel and served as a foundation for creating evaluations.

Since easyOEE was introduced, the evaluations required are available in a timely mannerin electronic form, which means we can react faster to any problems that may arise.”

Christian Henkelmann, Head of Door Systems AssemblyBrose (Sindelfingen plant)

“Thanks to the SMS notification service from easyOEE, we were able to react to malfunctions very quickly, even during these kind of shifts, which gave us several days of “additional” production time.”

“We have been using the easyOEE system for six months now.

Particularly beneficial to us is the malfunction notification by SMS. Because of the large demand for our AIDS quick test, we were compelled in recent months to produce the product round the clock in ghost shifts.

Thanks to the SMS notification service from easyOEE, we were able to react to malfunctions very quickly, even during these kind of shifts, which gave us several days of “additional” production time. I would like to once again thank FASTEC for all its help.”

Bernd Kölz, Trinity Biotech, Lemgo

“We were pleasantly surprised at how quick and easy it was to install easyOEE and how the software could be used almost intuitively.”

“The systematic capture of the OEE indicator plays a major role within the context of our GPS (Global Performance System).

We were pleasantly surprised at how quick and easy it was to install easyOEE and how the software could be used almost intuitively.

The simple and convenient configuration was of particular importance for us and convinced us that we could use easyOEE at different machines within our plant. The comprehensive evaluations allowed us to quickly replace our gut feeling with hard facts and to define measures that needed to be taken for the problems identified.”

Frank Lander, GPS Trainer, ZF Sachs AG, Bielefeld plant

“Since we began keeping records, we have witnessed a performance improvement of up to 15%.”

“After using the FASTEC system for around three years now, we can say that we are benefiting in particular from the parts tracking feature in the engine room. This gives us a quick overview of the current production status and allows us to take action quickly in order to countersteer any problems that crop up. Search times have been minimised and generalemployee satisfaction has increased as a result of the improved internal flow of information.

Since we began keeping records, we have witnessed a performance improvement of up to 15%.”

Alexander Schmeing, Managing Director, Holztechnik Schmeing GmbH & Co. KG, Ahaus

“Through improved monitoring of our machines for example, we have been able to realise productivity reserves of between 10% and 20%.”

“We have been using the FASTEC system for four years in our plastic moulding plant.
By now, the system is in place at over 80 machines here.
The system is doing great work for us. Through improved monitoring of our machines for example, we have been able to realise productivity reserves of between 10% and 20%. In addition, we were able to reduce cycle times by a value in the two-digit percentage range.

Through systematic documentation of the reasons behind malfunctions, we were also able tooptimise our tools.”

Dieter Henke, Henke Beschläge GmbH + Co. KG.