BMZ Poland
A company manufacturing batteries and accumulators for power tools, electric bicycles, cars and buses. Production at BMZ Poland involves many different projects, carried out on lines consisting of several to a dozen workstations (operated manually by employees), which form a production flow ending with the manufacture and quality control of the finished product or semi-finished product.
PROBLEM: production efficiency too low / underutilisation of resources available in the production process.
The customer tried to solve the low efficiency problem by verifying the assumed optimal cycle times or changing the crew size on the line, but the results were still unsatisfactory.
Imagine a large aquarium full of leaks – to maintain the correct water level, you have to constantly top it up. That was the case here. The customer had to put in a huge amount of effort to keep production at a level that was profitable. Adding more resources, even human ones, did not mean an increase in efficiency. This had to change!
SOLUTION: implementation of the IPLAS production monitoring and optimisation system.
The implemented IPLAS system allowed for precise observation of what is happening on the production lines. Thanks to data acquisition from finished product testers, we launched real-time reporting, which presented the progress and performance indicators of the process on an ongoing basis.1
The customer was able to accurately locate where problems occurred, their duration, and finally identify the causes, which made it possible to take the right steps in optimising the entire process. Currently, the hourly output and downtime on one of the selected lines are as follows:
