Success Story

Giesser sharpens blade production with process data.

Johannes Giesser Messerfabrik GmbH

Metal processing industry | Master office, production

Challenges

Visualization of production data from CimMETAL (ERP software for the metal processing industry) on monitors in the production hall and in offices

Solution

Connection of the ERP system CimMETAL via dedicated interface to Peakboard, provision of five different dashboards on four monitors in the production hall as well as one monitor in the master office

Advantages

  • Visibility of orders and production progress for all employees in offices and the production hall
  • Real-time data access at any time to show the actual state of the system
  • Greater motivation of employees through transparency about their own work performance

Time to value

14 days for the development of the interface, connection of the data source including interface development as well as the provision of a first dashboard

The customer

Johannes Giesser Messerfabrik GmbH.

As one of the world’s leading manufacturers of quality knives and accessories for professional users, Johannes Giesser Messerfabrik GmbH manufactures more than 8,000 professional knives every day at its headquarters in Winnenden, Baden-Württemberg. Around 2,500 forged or stamped knives for the catering and food processing industries are part of the product range of this traditional company. Giesser has been producing knives and cutlery by hand since 1776.

Today, the manufacturer of hand knives relies not only on craftsmanship but also on computer-aided work to keep pace with market developments. The latest IT coup of the knife factory: real-time visualization of production processes and data on monitors in the production hall and in the offices – so that all employees can see at a glance whether everything is running smoothly or where the final touch is still missing at any time.

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“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

Challenge

Illuminated production data.

“Every week we receive about 20 production orders. These result in requirements for sub-articles, which are then produced at various stations. The heart of the system is the blade production, which takes place in eight different work steps. Up to now, we used to map the order management via printed out plug-in cards, which the employees of the various groups had to obtain according to the work process,”

explains Björn Mutschler, head of the injection moulding department at Johannes Giesser Messerfabrik GmbH.

“However, this paper-based option has its pitfalls: paper printouts are not only expensive, but they contain rigid information that only corresponds to the facts at the time of printing. If an order is given a higher priority at short notice or the quantity required has changed, it was necessary to make sure that the circulating slips of paper were captured, reprinted and re-placed as quickly as possible. Errors in delivery dates or production quantities are virtually pre-programmed. We wanted to change that with the digital visualization of the orders.”

Since the ERP system CimMETAL used so far did not allow for the visualization of the data, a specific IT solution was needed to provide the desired transparency.

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Solution

Peakboard – small but mighty.

Giesser has now decided to go with Peakboard. The installation-free all-in-one solution offers all necessary hardware and software components for the aggregation of data from various source systems and their visualization in real time – packed in a smartphone small aluminum box. The management was initially sceptical.

“At first you only see a miniature computer and wonder why you should spend money on it when there are small single-board computers on every corner for less than a hundred euros,” Mutschler recalls. “When the small computer was finally able to show what it is capable of in the free trial from Peakboard, the okay came immediately.”

 

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Result

From production monitoring to vacation schedule.

“First, we visualized a complete overview of our production orders with all work steps on one dashboard,” Mutschler explains. “The basic idea was that we wanted to show the reports for each work step: For every production step, we feed back into the ERP system. When the punching process is completed, the employee at the punching machine reports back the quantity produced. This quantity is the starting point for the next operation and tells whether a smaller quantity needs to be completed or whether the quantity is sufficient. In the past we have always had major differences here. Because the number that was reported back was only in the ERP system, i.e. it virtually disappeared in a black box, the employee had no insight into whether he had entered his number correctly. With Peakboard he now has this transparency and we can be sure that the numbers are correct.

In the meantime, around 60 employees in production and two employees in the master office use a total of five different Peakboard Boxes. The shipping department uses a backorder dashboard to find out which backorders are available for which calendar weeks. Detailed information on which customer orders are affected is available at the click of a mouse. The Peakboard Box in the stamping shop visualizes key figures for the work steps such as stamping and hardening. Another Peakboard Box is located in the grinding and polishing shop.

“Every dashboard has several functions,” adds Mutschler. “By using function keys on a keyboard, we can call up several screens. For example, we have stored the shift and vacation schedules for the foreman’s office as a PDF document on the Peakboard Box with the general overview. Or: If a machine fails, the employees can manually set the dashboard to red, and at the same time an e-mail is sent to the employee responsible for the respective machine.”

The response of the employees was very positive. The production employees found it appreciative to be integrated into the process through Peakboard instead of working isolated from information about the current production status.

“Of course, with the newly gained transparency there is also more pressure, because now you can see if you are not meeting your target values” says Mutschler. “However, the employees perceive this pressure mainly in a positive light – as an incentive to achieve their production targets and to see how well they are performing”.

The main benefit of using Peakboard lies in the newly gained transparency across all production steps. Thus, production efficiency has been improved through faster and more precise processes. The elimination of paper-based order management and shift planning has also significantly reduced paper consumption.

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Future

Bright prospects for Peakboard.

Further dashboards with Peakboard or the perfection of existing dashboards are already in planning. Giesser is currently working on the implementation of a management dashboard that maps the visualization of business data such as cash flow without first having to request reports from the accounting department.

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Discover more

Interest aroused?

„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

Aquis Systems

Aquis Systems
“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
“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

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