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Beko

  • The customer defined the need for a system that would combine human resource management, production line monitoring and logistics optimization into one functional unit. The goal was to increase productivity, reduce errors and strengthen production quality.

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    In the area of ​​personnel management, it was necessary to:

    • Ensure control of operator training and the ability to plan substitution.

    • Maintain an up-to-date skills and abilities matrix for individual job positions.

    • Have an overview of the situation at the workplace in real time.

    • Evaluate the intensity of work based on quality, logistics, difficulty and safety.

    • Record work and enable the creation of motivation and reward systems.

     

    In production monitoring, the key was:

    • Automate the collection of information on the performance of machines and lines every second.

    • Monitor machine downtime, efficiency and all key indicators (availability, performance, quality) in real time.

    • Easily and quickly report data and evaluate KPIs.

     

    In logistics and material receipt, the following was required:

    • Support efficient processes already implemented at the customer.

    • Implement visual management of employees during material receipt.

    • Replace existing Excel processes while maintaining data conversion functions.

    • Plan loading and unloading in time windows.

    • Provide a modern design and user-friendly interface.

  • Our solutions, which we have implemented at Beko, combine production management, people and machines into one functional system. Thanks to the connection of the M2M Platform, visual management and effectiveness measurement (OEE), management and operators always have an accurate overview of the current state of production, which increases productivity, quality and speed of decision-making.

    • TLS - transport logistics system

    • ORS - operator resource system

    • OEE - overall equipment effectiveness

    • The pilot project took place on two top-loading washing machine production lines, where 114 work positions equipped with RFID readers with displays were monitored. Before starting work, operators log in with an access card and immediately see whether they are authorized for a given position, need retraining or can provide assistance.

    • HR managers gained a precise overview of training and occupancy of positions along with documents for payroll processing. Production and quality managers, team and project leaders monitor the status of operator logins and the progress of production in real time via a clear dashboard.

    • Thanks to the digital twin, it is possible to immediately identify critical tasks, detect potential poor quality and quickly assemble work teams according to the current availability of workers.

    • The pilot project was implemented in 2014. During the following year, we implemented the system on another 13 machines and 2 production lines.

    • The OEE tm system communicates with machines and production lines by exchanging data from the PLC via OPC server, OPC client, MOXA converters, PowerMeter. As soon as the system collected enough data, managers could start analyzing the most common causes of failures and make the first changes.

    • ​The manager can immediately react to changes in efficiency.

    • Three months after the order was placed, we delivered a fully functional first version of the system. We brought automatic data recalculation, advanced reports and graphs, as well as tools for planning and modeling future scenarios.

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    • By deploying augmented reality, information panels and traffic lights, we created a visual management system right in the hall, in which everyone can immediately see the current status without the need for communication. The main screen in the style of augmented reality simplifies working with the system and allows for quick and efficient production management.

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Efficiency, performance and quality under control

Production growth required the modernization of processes from material receipt to the entire production. The new information system replaced Excel spreadsheets, enabled data validation, quick overviews and information sharing in real time.

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We implemented a solution for precise measurement of machine and line performance, which will reveal the causes of suboptimal production – from failures and product changes to short downtimes or missing material.

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In the area of ​​personnel management, the system ensured control of training and work authorization, simplified shift planning, enabled rapid substitution and brought detailed data for HR and quality improvement.

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The result is an integrated solution that increases efficiency, minimizes errors and maintains top production quality.

80 %

time to find an operator

2 weeks

reducing the time needed to train the operator

Results

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Savings. Speed. Accuracy.

Reduction of the most common unplanned production downtimes and reduction of direct and indirect costs caused by poorly functioning equipment.

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In cooperation with Beko Poprad, we implemented the PIEx and OEE systems and are preparing the deployment of M2L.

PIEx brought a return on investment within one year, saving a work shift on material receipt, stabilizing processes and reducing logistical errors. We expanded the system with Kanban, a packaging catalog, advanced reports, inventory and integration with SAP HANA.

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OEE improved the measurement of machine efficiency, revealed bottlenecks, reduced downtime and accelerated repairs. Thanks to the expansion with structured data collection, automated supply and faster shift setup, the operator training time was shortened to two weeks and the search for a worker was accelerated by 80%.

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In the future, we plan to implement M2L (Manipulate to Light), also known as pick to light – a visual navigation solution that will further increase the accuracy of component handling and improve material flow in production.

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