GOING FULL THROTTLE TO THE DIGITAL FACTORY
More and more companies from the machining industry are using the ValueFacturing system developed by MR in order to make their production processes more effective and future-proof on their way to becoming smart factories. Stangl & Co. GmbH Präzisionstechnik, based in Roding, Germany, was among the first to implement the innovative assistance system from Reinhausen. The company, based in the Bavarian Upper Palatinate region, has now also calculated precisely how much this system has benefited them. And the results are impressive!
Stangl & Co. GmbH manufactures individual and series-produced precision components – which must satisfy tolerances accurate to a thousandth of a millimeter – for customers from the automotive industry, aerospace, electronics, medical technology, the engineering sector, tooling system technology, and high-tech industries. Its customers also include a sister company which manufactures the exclusive, lightweight super sports car, the Roding Roadster. Since 2009, Stangl & Co. has been using the ValueFacturing assistance system from Maschinenfabrik Reinhausen for its production management. The result: an increase in the company's efficiency and productivity of around 70 percent.
Johann Hofmann developed the ValueFacturing assistance system for MR. While still bearing the product name MR-CM, it was first subjected to comprehensive testing and examination at Reinhausen itself and found to be of good quality. The system has been in continuous use since then, but now under the name "ValueFacturing" since the update to version 3.0. Hofmann now heads the MR business area named after his software, which has successfully marketed the manufacturing assistance system to other companies in the machining industry. During his factory visit to Stangl & Co. in Roding, the managing partner Hans Stangl and the project manager Florian Dürr reported on the progress they have achieved since the assistance system was introduced to NC manufacturing.
The conclusions of both were overwhelmingly positive. Thanks to ValueFacturing, their company has made enormous strides toward implementing a digital factory. Non-productive downtimes have been eliminated to a large extent, set-up times have been reduced dramatically, and there is now far less need for replacement tools. All this has led to an increase in productivity and efficiency of around 70 percent. As Hans Stangl explains: "In 2009 we reached a point where our manual manufacturing control system could no longer keep pace with our continuing growth and the numerous parts that had to be machined as a result. For this reason, we decided to invest in the assistance system from Maschinenfabrik Reinhausen." Florian Dürr, who implemented ValueFacturing at Stangl & Co. and is responsible for maintaining the system, adds: "A great advantage is that MR works with this manufacturing management solution itself. The benefits are tangible in the highly practical nature of the system and in the continual development and adjustment of the system to meet user requirements."
The integration of the assistance system at Stangl & Co. has led to a complete re-organization of production. In the five years since NC manufacturing was made completely subject to management by the software solution, over 170,000 setup orders have been processed, of which 70,000 were SFP and around 45,000 were NC programs. "In order to handle this huge volume of orders, under our old system we undoubtedly would have needed 20 additional qualified employees – and those are hard to find these days," adds Hans Stangl. Since the start of the project in 2009, the company's sales revenue has almost tripled. During this time, the number of employees also grew by 110 to 253, and the number of CNC machines was increased from 25 to 60. "However, having well-trained and motivated people involved in your company continues to be important," concludes Hans Stangl. "Without them, having the best software counts for nothing."
VALUEFACTURING BY MR
ValueFacturing is so far the only completely web-based software solution for manufacturing management which connects all systems and roles in a manufacturing process into a network and enables bi-directional, online communication in real time. At the same time, the system can enhance collected information in an intelligent way. Unlike with conventional data-management systems for manufacturing, this creates a consistent, electronic workflow which makes manual data input and forwarding unnecessary.