In the modern manufacturing landscape, companies such as the Siemens appliance plant in Amberg / Cham are faced with the challenge of continuously improving their production efficiency….

Smart manufacturing: optimization of material flow and cost savings through data-based production planning

In the modern manufacturing landscape, companies such as the Siemens appliance plant in Amberg / Cham are faced with the challenge of continuously increasing their production efficiency in order to meet growing market needs. As specialists in digital transformation and digital shopfloor management, we were commissioned to support the plant in optimizing its material flow. Our goal was to create a smooth and accelerated production flow that shortens delivery times and maximizes customer satisfaction. Find out more about our approach, the results achieved and the positive feedback from our customers.

The challenge

Inefficient coordination of prefabrication and assembly lines

Siemens’ Amberg / Cham appliance plant faces a significant challenge: the lack of synchronization between prefabrication and assembly lines meant that prefabrication can not keep up with the speed of the downstream assembly lines. The result is a bottleneck that hinders the overall output of the value stream and therefore the ability to respond appropriately to customer demand. A highly diversified product mix leads to a complex production landscape with multiple production lines, each with different capabilities and levels of automation. In addition, the set-up processes were time-consuming, leading to delays and inefficiencies.

Our customer expresses a clear wish: “As a plant, we want to be able to respond flexibly to customer requests as well as react in real time to other production-determining influences. To achieve this, we want highly available, optimal production planning at all times.”

The solution

Data-driven, dynamic production planning through real-time data and predictive analyses

To overcome our client’s existing multiple challenges, we implemented a customized, data-driven solution based on our AdvancedFlow-Framework (AdvFlow), which is based on data collection both directly from the store floor and from IT systems. By connecting IoT sensors and integrating machine learning technologies, we are able to enable dynamic production planning based on real-time data and predictive analytics.

Components of the solution:

Data collection: by connecting IoT sensors and connectivity agents, we are able to realize seamless data collection directly from the store floor. This formes the basis for data-based analysis and optimization of the material flow.
Intelligent algorithms: A specially developed algorithm takes care of evaluating the collected data. It identified optimal order sequences and enabled predictive maintenance in order to minimize downtimes and maximize machine availability.
Employee training: Intensive training of plant personnel ensures that the new technology is used effectively. Employees are empowered to take full advantage of the system and increase production efficiency.
Real-time optimization: “AdvFlow” adjusts production planning in real time, enabling a flexible and dynamic response to changing conditions and customer requirements. This agility is crucial for a modern manufacturing environment.

By embedding AdvFlow digital solutions into the production process, we are able to make manufacturing more flexible and increase productivity.

Our customer put it in a nutshell: “Digital solutions in production open up opportunities for us to respond more flexibly to customer requirements and generate productivity at the same time. AdvFlow helps us to manage production orders optimally – based on algorithms and supported by live data from our machines.”

The result

Optimization of material flow and cost savings through data-based production planning

The introduction of the new, data-supported optimization leads to a significant increase in efficiency for our customer. Set-up times are significantly reduced thanks to an optimized order sequence, which shortens throughput times and increased responsiveness to customer requests.

The benefits of the solution include in detail:

Increased production efficiency: reduced throughput times and optimized set-up processes
Cost savings: Reduced operating costs through more efficient use of resources
Increased flexibility: Improved ability to adapt to market fluctuations and customer requirements
Employee satisfaction: relieving staff of complex decisions through the use of supporting technologies
Scalability: Highly flexible, adaptable solution through the use of scalable cloud architectures

By implementing AdvFlow, Siemens Gerätewerk Amberg / Cham is able to realize considerable net savings. Overall, our solution makes a significant contribution to the digital transformation of the Siemens appliance plant, which sustainably strengthens its competitiveness and sent a clear signal to the market: We are ready for the future of manufacturing.

With the introduction of AdvFlow, Siemens Gerätewerk Amberg / Cham has taken a significant step towards the digital future. The successful implementation of the project demonstrates the company’s innovative strength and commitment to achieving top performance in manufacturing. As a digitalization partner, we are proud to have accompanied this journey and look forward to supporting other industrial companies on their path to digital excellence.

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