FUCHS LUBRITECH takes another decisive step into the digital age. The tablet has superseded manufacturing instructions on paper thus reducing error rates, improving work safety and ensuring smooth production processes.
Only one step of the entire manufacturing process in the production of FUCHS LUBRITECH is communicated the conventional way. “At the beginning of their work day, employees receive their work orders on paper. Previously, such orders included all data related to the required raw materials and accurate instructions for the manufacture of the product. Today these documents are largely empty – except for one code“, reports Michael Scherer, Team Leader for the CASSIDA and CEPLATTYN product lines at FUCHS LUBRITECH GmbH in Kaiserslautern. “This is when the tablet comes into action“. On the tablet, the order is called up using the code and started automatically requesting the required raw materials from high-bay warehouse. “In the first step of the manufacturing instructions, the raw materials are listed again,” Mr. Scherer explains the processes. “Moreover, the risks of a particular raw material and the mandatory protection measures, such as wearing personal protective equipment are pointed out. Ultimately, this increases our internal occupational safety and health“.
The next processing step includes the preparation of the required machines and equipment, e.g. thorough cleaning and the addition of the respective “ingredients”. “This process is about which raw material have to be added when, how long the mixture is to be stirred or which parameters must be set,” Mr. Scherer explains. “Each phase is started by a simple touch on the tablet and completed by a confirmation including signature. This procedure leads the employee step-by-step through the production process.” Another special benefit of the tablet: it scans the raw material bar code and helps to avoid confusions. “Error rates were reduced significantly,” Mr. Scherer says. Once the mixture is perfect, a sample is taken and sent to Quality Control. If QC does not require any additional adjustments and gives the go ahead, the employee can book the finished product to inventory and conclude the order.
Production staff are convinced that the introduction of the tablet creates significant added value.
“In January 2016, this paperless production was launched and has proven beneficial despite the little extra effort during the initial implementation phase,” says Mr. Scherer. “Fewer errors occur when using different raw materials and the awareness for work safety is raised, since it is constantly emphasized throughout the entire production process.” The production staff of FUCHS LUBRITECH was involved in the development and implementation of the software.
The conversion offers even more added value: due to the process automation, the manufacture of certain products could not only be standardized and simplified – digital control also enables online documentation and the acquisition of numerous useful data. This contributes to more transparency and ultimately to continuous process optimization
Most important is the impact this paperless production has on FUCHS LUBRITECH’s customers. One of the company’s core competences is inspection, maintenance and repair of large sized open gearboxes in the raw materials industry by their service engineers worldwide. Service data of regular on-site assignments is stored in the "FLT Inspector", a state-of-the-art documentation system and made accessible to the customer at any time. The FLT Inspector is also available as an app and enables the customers real time access to all maintenance information worldwide. This comprehensive service package provided alongside CEPLATTYN lubricants makes gearbox life cycles of more than 40 years possible.
