Success Story: MUNSCHPlastic Welding Technology GmbH

The Customer

MUNSCH Plastic Welding Technology GmbH has specialized in the manufacture of handlable tools for welding thermoplastics for around 40 years and is now regarded as the world's leading supplier. The products are developed, produced and tested in Ransbach-Baumbach in the Westerwald region of Germany. The plastic hand-welding extruders and hot wedge welding machines are used all over the world.

Challenge

In addition to production, the range of services offered by the family-owned company also includes the repair of these devices.
In order to automate the repair process in terms of increased efficiency and customer satisfaction, the various process steps were digitized. The entire process was depicted, from the submission of the defective extruder, the analysis of the repair requirement, the preparation of the cost estimate and sending it to the customer, through the initiation of the repair after approved quotation, to the packaging/goods issue of the repaired device. The booking of the individual steps is supported by barcodes and corresponding scanners by the employees in the workshop.
This was followed by the visualization of the information. “We started with a so-called card board, a magnetic board on which the various stages of the repair process are depicted. Each repair order was displayed on a kind of business card, printed out, attached to the card board and moved up depending on the processing status. The board was hardly ever up-to-date because the repair cards were moved too late or not at all. With this method, we missed the actual goal of providing more transparency in the process,” explains Oliver Herz, Head of Application Development at the MUNSCH Group.
The media discontinuity between the digitized recording of process steps and the manual procedure of visualizing process progress was to be eliminated by introducing a digital visualization solution.

Solution at a Glance

Challenge

Digital visualization of the processing status of repairs in the workshop

Solution

Digital visualization of the processing status of repairs in the workshop

Advantages

  • Elimination of the previous manual effort for the visualization of process status during repairs
  • Seamless media implementation from data collection to visualization
  • Fast acquisition of information via a central monitor in the workshop
  • Increased transparency as added value for customers and trading partners during workshop visits

System Environment

APplus (ERP-System based on Microsoft SQL Server)

Time to Value

One day to provide an operable Peakboard with two different screens.

Contact

Location Ransbach-Baumbach

MUNSCH Plastic Welding Technology GmbH
Im Staudchen
56235 Ransbach-Baumbach
Germany

Phone: +49 2623 898-0
Fax: +49 2623 898-80
Email: info-kst@munsch.de
Website: www.munsch-kunststoff-schweisstechnik.de

The Solution

Oliver Herz's own boss put him on the right track. He brought the visualization solution from Peakboard GmbH into play – an installation-free all-in-one solution based on a WLAN-capable, smartphone-small aluminum box with complete technology for the aggregation of data from various sources and their visualization in real time. A central server is not required as each Peakboard visualizes the data independently. The Peakboard directly accesses a data source, for example an ERP or warehouse management program, via Wi-Fi or LAN, aggregates the data for the visualization and transmits it via an HDMI cable to the desired (large) screen, for example in the production hall. Data and visualizations can be adapted independently at any time without external support via PC or notebook.

“I had never heard of this solution before and first figured it out on the Internet. The idea behind the product inspired me, so I requested a trial version, which convinced me in practical use.” Potential customers have the opportunity to test the software and hardware free of charge for 60 days. Within just one day, the leading application developer of the MUNSCH Group developed a Peakboard with two screens for use in the workshop and made it production-ready.
“The support provided by Peakboard was also very good,” adds Herz. “The response time for questions is less than a day. What I also liked: During the implementation period, the support team regularly proactively asked if there was a need for support”.

Application and Benefits

The ERP system APplus, which is based on Microsoft SQL Server, serves as the database. The tables accessed by Peakboard are updated every five minutes.
A 65-inch monitor hanging in the workshop is used. On the one hand, the chronological goods receipt is visualized – i.e. the number of sent in extruders in need of repair. The pillars in red, yellow and green show which welding equipment has been in stock for how long: more than two days, two days or one day and less.
The mechanic can see on the screen whether he has more new goods receipts or more released quotations and accordingly prioritize which works he performs first: repairs or analysis of repair needs as a basis for new quotations. “Or whether, if both the value of the incoming goods and the value of the released quotations increase, another mechanic needs to be involved,” adds Herz. In addition, the processing time of an order is displayed – both the average of the year and the average value of the last completed calendar week.
On the other hand, a list of all service orders with service number, customer, model, date of goods receipt and most recent booking is displayed in a two-minute change with the goods receipt screen – in other words, each process step in the repair process and the number of days since the last booking.
By using Peakboard, MUNSCH benefits on the one hand from time savings, as Herz explains: “The colleagues complained about the manual effort involved in the card board variant we had previously visualized. The elimination of the additional work by moving the cards was, of course, well appreciated.”
In addition, transparency has increased significantly. “We are now completely visible in our process, which allows employees to work in a structured way without having to look at any lists. A quick look at the Peakboard and they know how it works at the moment.”
As Herz reports, Peakboard also makes a contribution when it comes to external impact: “Our company philosophy includes a clean, tidy, structured workshop in which we frequently welcome trading partners and customers. We see the large display with the current repair status as a perfect complement to the positive appearance of our workshop. We always experience a small 'wow effect' with the visitors of the workplace”.

Future

The sister company MUNSCH Chemical-Pumps GmbH plans to also use Peakboards for process visualization in the future. “The day before my vacation, I hung up the board in the morning. In the afternoon, I already had a colleague in my office who wanted a Peakboard for his department,” concludes Herz.