What were the challenges to be solved and what specific benefits were achieved?

Depending on the size of the produced ROTAMASS flow meter, differing packaging times and the corresponding spatial requirements for packaging work are needed. The Industrie 4.0 solution shows all devices in the last seven production steps, including size and current location. Using this transparency, it becomes possible to forecast when a device will be supplied to shipping. The Industrie 4.0 solution helps companies to use their resources more effectively. Orders with a batch size of 1 can also be processed.

How can the Industrie 4.0 approach be described?

The entire digitisation is displayed in real-time. The shipping department as well as production management can view the current situation in the production line any time and take action in order to, for example, process a single device missing for completing a customer order with priority.

What could be achieved?

The newly achieved transparency makes it possible to use existing resources more specifically. This affects better planning of personnel capacities in the line and in logistics as well as more efficient use of the existing packaging and storage space.

The worker must register at each workstation using a code card. The system will not only check whether the worker is authorised to work in that location but will also notify the authorised employee immediately if a change in regulations and/or work process has taken place for that workstation. The employee must then read the changes immediately and confirm to the terminal that s/he has understood them. This process has the advantage that even tasks carried out by job hoppers can be properly carried out as they are aware of the latest information. That way, some trainings can also be executed online.

What measures have been taken to achieve the solution?

RotaYokogawa has been active in Industrie 4.0 since early on. Since 2013, the company has been a member in the innovation association for production work 4.0 of the research institute Fraunhofer IAO. The idea for the project described here and its subsequent realisation occurred within this cooperation.

What can others learn from it?

The solution demonstrates that medium-sized companies with orders of a batch size of 1 can use the advantages of Industrie 4.0 as well and thereby create an added value for the company.