BMZ - Case Studie

BMZ Poland – producer of batteries, accumulators for electric tools, electric bicycles, cars and buses.

Production at BMZ Poland includes many different projects, carried out on lines consisting of several / a dozen workstations (manually operated by employees), constituting a stream of production that ends with the manufacturing and quality control of the both finished product or semi-finished product.

Problem

Too low production efficiency / incomplete use of resources available in the production process.

The client tried to solve the problem of low efficiency by verifying the assumed optimal cycle times or changes in the brigade size on the line, but the results were still unsatisfactory.

Imagine a large aquarium full of leaks – to maintain the right level of water, you have to add it constantly. This was the case here. The customer had to put in a lot of effort to keep production at a level that was profitable. More resources, even human resources, did not mean increased efficiency. It had to be changed!

Solution

Implementation of the IPLAS production monitoring and optimization system.

The implemented IPLAS system allowed for precise observation of what is happening on the production lines. Thanks to data acquisition from testers of finished products, we launched real-time reporting, which presented on an ongoing basis the progress as well as performance indicators of the process.

The client was able to accurately locate where problems occurred as well as the duration of the problems, and finally indicate the causes of these problems, which enabled taking appropriate steps to optimize the entire process.

Currently, the hourly capacity and downtime on one of the selected lines are as follows:

As you can see, the productivity is close to the assumed targets almost throughout the time of the production, the hourly productivity is dominated by green bars, and the periods of detected line stoppages are decidedly minor. Compared to the status quo at the time of implementing the IPLAS system, the production efficiency has significantly increased.

Will it be like that for you?

IPLAS will not solve the problems that affect the low production efficiency for you, but it will precisely indicate their occurrence and duration. Thanks to proper data analysis, you will be able to take action aimed at problems found and ultimately improve the efficiency of the production process.

Do you have any questions? Would you like to see how it works? Schedule a free meeting with our representative.