Author: Dr. Caren Möhrke, Marketing Services Düsseldorf
Therefore, an additional highlight is that the other sectors in the Grevenbroich plant can take over the functionalities of the system with complete independence. And that is only because the organizational structure of the existing IT systems does not have to be deeply accessed. Due to the manageable costs and a project duration of no more than three to five months, other Hydro plants are already watching the development in Grevenbroich with interest.
The FGS of the PSImetals software is an outstanding feature and above all it is a necessary basis for the modernization of existing product management systems. Only if real transparency down to the single piece is given, transfer times can gradually be further reduced and thus in fact also the circulating stock. And exactly that is now guaranteed.
This has been achieved by the experts of 4Production with their production expertise in the aluminum industry with optimal single-piece-related stock transparency at the storage site level. It is the starting point for every further efficiency increase, such as reduction of the work in progress, real-time fine planning and diverse further optimization approaches. The particular feature of the forklift guidance system is the smooth integration into the existing production organization. So the foundation is laid to - successively and application-related - modernize existing production control applications. The information on upcoming transports and stock on hand are communicated to the forklifts by WLAN via the autonomous FGS.
The fast locating of coils, the optimal management of the material flow and a clear reduction of search times not only create high efficiency but also more motivation among the employees involved. 90% of the search time is omitted, 80% of the customer orders are now bundled in storage; the right coil at the right time at the right location and the suitable forklift is no longer coincidence.
The transparent, paper-free management system has an additional advantage: It is absolutely flexible. Should the storage area be changed or expanded, it can be newly organized in the future at any time by the one’s own employees. And in fact manually.
Hydro’s rolling mill in Grevenbroich is one of the global leaders for high-quality aluminum strip and foil products, which in part are also refined and finished here. The location stands for semi-finished products which, for example, are further processed in the packaging, automobile and printing industry. The business unit Strip was the first pilot production sector, in which the forklift guidance system (FGS) of the market standard PSImetals was commissioned, which primarily does one thing: arouse desire.
Slim, fast, efficient: This is the flexible starter solution for the new management system for forklifts at Hydro in Grevenbroich. Since it immediately brings a tangible benefit and makes work much easier, the drivers become increasingly satisfied. Accordingly, those who are not yet working with the system become impatient. The previous method of transporting the coils on demand, which came along with long search times, manual document management, material damage due to stock transfer and unnecessary waiting times up to machine downtime did not make anyone really happy.
Internal marketing, convincing people - all that was not necessary here: the system’s benefits were particularly and directly communicated by the first users. In this way the implementation and commissioning sort of was drawn into operation by the employees themselves. Due to the gradual introduction of the retrofitted forklift trucks, time and again situations arose, in which forklift drivers complained that they were not yet benefiting from the new system. A better reference and acceptance can hardly be desired in such a project. Other sectors in the factory now want to participate in the process as quickly as possible.
Product & Solutions: Forklift guidance system in the Hydro Grevenbroich plant
