Success Story

Improving the flow of
faucet production.

Aquis Systems

Sanitary technology | Production

Challenges

Get information about quantity and quality to the employees at the right time

Solution

Extraction of data from SQL database for real-time information on output, defect rates and defect types

Advantages

  • Fast implementation
  • Higher motivation of employees through transparency of their work performance
  • Transparent and automated data preparation

Time to value

One working day for the creation of the first dashboard and integration into the system

The customer

Aquis Systems.

Based in Rebstein, Switzerland, Aquis Systems AG is an OEM (Original Equipment Manufacturer) that develops and manufactures electronic solutions for sanitary installations in the public and commercial sectors, from complete electronic faucets to water management systems. Components for hydraulics sensorics/electronics, communication (APP to IoT) are also part of the scope of services. Founded in 1995, the company employs a staff of 300 at three locations.

read more
„After just a few brief discussions with Peakboard and watching a few online videos that they provided, I was able to design the interface myself without any help from the Peakboard team, down to being able to integrate our corporate identity.”
Denis Maljkovic, Head of Production and Industrialization at Aquis

Challenge

A bloated excel spreadsheet and severe time delays.

At each of the 15 production stations, a maximum of three skilled workers install sensor-controlled faucets by hand. Each station has a tester that inspects electrical and mechanical components, leak tightness, and the software and hardware of the end product and then transfers the results to an SQL database. The tester then imports the data into an Excel spreadsheet for analysis to optimize processes and improve quality. This is how the company obtains information on statistics such as the production error rate and the output quantity at the end of the day.

“Instead waiting until after a shift to know how much we have produced, we want to know this during the shift so that we can respond earlier,” says Denis Maljkovic, Head of Production and Industrialization at Aquis. “On top of that, Excel-based shop floor management in the morning simply takes too much time. Given the amount of data, an update can sometimes take up to half an hour. The subsequent analysis is also time-consuming because we first have to create the right view. This is where we quickly come up against the limits of our programming skills.”

In some cases, the process may take several hours because the volume of data rapidly increases. Communicating up-to-date information about unit counts and quality to employees soon enough is impossible. Maljkovic has to delegate or automate because his capacities are exhausted.

read more

Solution

Operational excellence platform.

Maljkovic’s team was able to make two mechanical problems in the inspection process transparent immediately at the start. The previous method reported some manufacturing elements as defective, even though they were not.

The main benefit, though, is a significant increase in the speed of data preparation and the quality of the information.

“What took hours before is now done in real time and is automated,” Maljkovic sums up.

This improves communication with other departments, including those that are only sporadically involved in shop floor management, such as internal sales or executive management. All in all, interest in the order status has increased noticeably since real-time information about production is available.

“Now we communicate very efficiently about why there are which defect rates for which defect types – software, hardware, or mechanical. Information is clearer. Before that, it was all on paper. Going into great detail there was complicated. Now we can clearly show what we are talking about directly on the dashboard without printing it out,”says Maljkovic.

The evaluations provide a common basis for everyone involved so that targeted optimization measures can be identified efficiently while increasing their acceptance.

read more

Result

Real-time and historical data.

In an initial workshop lasting around four hours, a dashboard was created and then tested in the day-to-day operation.

“We immediately ran the initial draft in real time to see whether the data was correct,” says Maljkovic. “The productive collaboration was key in helping us build a well-developed dashboard very quickly.”

In a second workshop, Aquis and Peakboard used the findings from the testing phase to finalize the details.

The dashboards visualize daily, weekly, monthly, annual, and real-time output for each location. Along with output, the dashboards show the current orders per production station and the level of achievement, including pass/fail inspections. The company can view the status quo of all production stations as a whole. Plus, it can also analyze each production station in depth to reflect on performance with its team and quality managers. Peakboard’s operational excellence platform accesses the SQL database directly to extract the previously defined data defined.

read more

Future

Data analysis on all production sites.

In the future, Aquis will visualize additional information about each of its production stations, for example. with an Andon Board that displays material availability. Right now, employees still trigger the signal for a material shortage manually, at which point a warehouse worker delivers the goods. This can take several minutes. To decrease this margin, Aquis will first measure the downtime caused by material shortages.

The next step is to show quality at the level of a specific component. Maljkovic explains,

“We now have a lot of ideas on how to digitally record our production, which we are gradually specifying and implementing. Our initial experiences have made us get creative.”

Although the SQL database records data from every location, visualization is currently only available in Switzerland. Yet as soon as all the necessary information has been compiled there, Aquis will also set up Peakboard dashboards at its other locations.

read more

Discover more

Interest aroused?

“For me, digitization also means generating real added value from existing data. And that’s exactly what we are doing with Peakboard: We provide employees with the information they really need in their daily routine – in a simple manner and exactly where they are needed, whether in the office, in the factory hall or on the forklift.”

Christian Leins, Head of Software Development at Bizerba

Bizerba SE & Co KG

Bizerba SE & Co. KG
“The effects have been consistently positive. The overall effectiveness of production has increased, and our planning is more accurate. Our processes have also been significantly accelerated thanks to the MES functions. Our teams are even more motivated than before, and they are really leaning into the friendly competition to achieve the goals.”

Mityo Dryankov, Director Maintenance, Innovations and Technology at Bon EOOD.

Bon EOOD

Bon EOOD
„From the first minute the employees loved Peakboard and the visualization. They are much more motivated because they see the daily goals and workload. More transparency in the whole company.“

Jordan Marlin, Manager Operational Technology, Industry 4.0 Engineering at BWI Group

BWI Group

BeijingWest Industries (BWI Group)
“We were able to set up the dashboard so that we could self-manage it: We downloaded the Peakboard Designer, chose the components to be displayed, and then configured and set up the Peakboard Box. This was a simple task due to our knowledge of automation structures. There was also a lot of learning by doing, which was fun. We were able to put the first implementations into live operation after just a week.”

Ralph Sagberger, Head of Organization & Production at Corratec

Corratec

Corratec
„With Peakboard, information is now quickly and transparently available right where it is needed.“

Sandra Schubert, Process Optimization at GBA Group

GBA Group

GBA Group
“Only Peakboard met our requirements for standardized interfaces to various systems, especially SAP, as well as the visualization of shop-floor data in real-time and with no programming required.”

André Fimpel, Head of Lean Management at Helmut Fischer GmbH

Helmut Fischer GmbH

Helmut Fischer GmbH
“We like the easy usability of the Peakboard Designer and that complex designs can still be created with LUA. The excellent support from Peakboard and the speed with which new functions are implemented is clearly worthy of mention.”

Marc-Philip Stüttern, Head of IT at Joh. Clouth GmbH & Co. KG

Joh. Clouth GmbH & Co KG

Joh. Clouth GmbH & Co. KG
“By using Peakboard we have become faster and more precise in our processes. The newly gained transparency also reveals further potential for process optimization, which we will gradually exploit.”

Björn Mutschler, Head of Production at Johannes Giesser Messerfabrik GmbH

Johannes Giesser Messerfabrik GmbH

Johannes Giesser Messerfabrik GmbH
“With Peakboard, we have achieved efficiency through greater transparency. Employees can see at a glance right from their workplace what the current status is and can steer their work steps accordingly.”

Oliver Herz, Head of Application Development at MUNSCH-Group

Munsch Plastic Welding Technology

Munsch Plastic Welding Technology
„We needed a centralized display of current production data on an andon-board to take the next big step toward operational excellence. Employees should be able to see the status of their plant in real time: What is running on my machine right here, right now? The solution selected also had to be able to become the standard in our group to avoid having to work with a large number of different systems.“

Mario Pichler, Head of Automation at Pankl Racing Systems Inc.

Pankl Racing System AG

Pankl Racing Systems AG

Get started right away!

Peakboard now
test free of charge.

Scroll to Top