Assembly and logistics in sync with digital Andon boards
Kässbohrer Geländefahrzeug AG
challenges
Replacing the self-programmed visualization solution with flexible, customizable Andon boards for real-time visualization and synchronization of assembly, warehouse, logistics.
solution
Introduction of Peakboard, connection of various data sources via SAP interface, Siemens S7 and OPC UA for real-time data, provision of Andon boards for assembly, warehouse and high-bay warehouses and logistics, etc.
benefits
- Real-time visualization of assembly, warehouse, logistics → transparency across the line
- Common accord for all areas → reduced downtimes, shortens response times and stabilizes output
- Event-controlled data transfer (OPC UA) → less data volume, higher accuracy
Time to Value
Kässbohrer Geländefahrzeug AG, based in Laupheim, is one of the world's leading manufacturers of special vehicles for runway, beach and environmental care. The portfolio includes BeachTech beach cleaners, PowerBully commercial vehicles and digital solutions such as SNOWsat. However, PistenBully is at the heart and best-known brand of the company: Since 1969, red snow caterpillars have shaped the preparation of slopes in ski areas all over the world. With a global market share of over 50 percent, PistenBully stands for innovative, reliable and efficient technology under the toughest conditions. The offering is complemented by digital fleet management solutions such as SNOWsat, which increase efficiency, precision and resource conservation in slope maintenance.
Peakboard provides us with a tool that makes visualization and digitization in the sense of Industry 4.0 easy and practical implementation.
From rigid system to agile production management
At the Laupheim site, the special vehicles are manufactured using very flexible, customer-specific assembly processes. Precise timing and smooth processes are crucial here. To make production even more efficient, the assembly line was redesigned according to lean principles. A central goal: all stations should work synchronously and status and problems should be immediately displayed on Andon boards for everyone to see so that the team can react quickly. Although the previous proprietary visualization solution based on mini PCs provided initial approaches, it was rigid, unstable and not very flexible. Changes to the layout or functions were also only possible with extensive programming knowledge.
, “There were seven Andon boards in total — six on the chassis in production and one in the master's office. The display ran on a permanently configured monitor and was not flexibly adaptable: no simple redesign, no additional buttons but just a rigid display,” confirms Alexander Friese, internal IT system integrator, Kässbohrer Geländefahrzeug AG
That's why PistenBully was looking for a solution that was easy to adapt, visually clear and technically reliable, and thus supported the lean assembly process.
From internship project to production solution
The special vehicle manufacturer found what he was looking for via Internet research at Peakboard. The decisive factor was the ability to connect almost any data source and to use monitors with data extremely flexibly; compared to the market, there was no provider offering this flexibility at that time. Even the first demos showed that “peripheral areas” such as warehouses and high-bay warehouses can be easily mapped. “The ideas were immediately there as to what else we could implement — and relatively simply,” says Michael Hofmann, production planner, Kässbohrer Geländefahrzeug AG. “It was precisely this simplicity that we have lacked so far and has always been an obstacle. Peakboard simply brought them along.” Peakboard provided two devices for the practical test at short notice.
“Getting started was so easy that our intern was able to set up the first Peakboard, which is now productive, almost independently with a little help from Peakboard Support. The numerous explanatory videos available online were also helpful,” remembers Michael Hofmann.
Based on this experience, PistenBully directly ordered 16 devices and quickly used them in production.
“Expected teething problems occurred during the start-up phase,” says Alexander Friese. “The managing director of Peakboard came to PistenBully on site together with a specialist and looked at the implementation in detail. On this basis, Peakboard was optimized (more efficient queries, lower resource requirements) and we were provided with more powerful hardware. ”
The ongoing service and support proved to be very reliable: PistenBully had a permanent contact person in support and received practical solutions to e-mail inquiries, usually on the same day. Through close cooperation, the team built up valuable, deep know-how unplanned. As an early adopter, PistenBully was involved in the development and was able to precisely incorporate its own requirements.
“The result: a smoothly running solution that we were able to scale quickly, and a partner who learned together with us what is really needed in practice,” says Alexander Friese in a nutshell.
Andon boards for production, logistics, warehouses, etc.
There are now over 20 Peakboard boxes in use. The focus is on production: On the chassis belt, six Andon boards visualize the status of cycles 1 — 6 and the pre-assembly engines, support frame and sequence center.
A traffic light system signals the need:
- Green = on schedule
- Yellow = jumper assistance (e.g. rework)
- Blue = Request logistics
- Red = master alarm/band stop
- White (in 6th cycle) = collection of the transport trolley from the paint shop
The frequency is shown by a continuous bar and countdown; target and remaining times are immediately visible. Deviations are visible, targeted support is requested, and cycles are kept in sync. This reduces downtimes, shortens response times and stabilizes output. The Siemens PLC provides the required data. Initially, the connection was implemented via the S7 interface with a fixed query interval. This generated unnecessary data traffic and caused the time display to lag behind. On the recommendation of Peakboard Support, we switched to OPC UA: Since OPC UA is event-controlled, only the changed data set is transferred when a value changes.
“This reduces the data volume and ensures that the display is immediately synchronous when the minute changes,” explains Alexander Friese.
Peakboard-based Andon boards are also used in hose storage, door assembly, paint workshop/welding, cab and chassis assembly, completion, acceptance and quality assurance. In the master's office, an overview board summarizes the chassis, cab and completion lines. In logistics, two Peakboard Andon boards for the high-bay warehouse (pallets) and for the small parts warehouse (boxes) visualize material flows based on SAP data.
The monitors display:
- Current picking and shipping orders,
- priorities,
- Processing status (open, completed, ongoing waves).
This allows employees to see at a glance which orders are next, where there is an acute need and how many waves are running. As a result, pallet and box warehouses can reliably operate the line every three hours.
Assembly and logistics in sync
From the first applications, a consistent system developed step by step, which today combines assembly, logistics and quality assurance. The central benefit lies in a joint effort across all areas.
“Areas such as assembly, completion and warehouse/logistics that do not see each other in everyday life work according to the same cycle time and follow the same “clock.” Cycle time, material flow and work progress remain in sync. As a result, there is no need to idle when changing vehicles and line output remains stable,” says Michael Hofmann.
If a clock screen or data source fails, a ticket is automatically triggered. IT immediately sees where the problem is and can intervene in a targeted manner. Remote access is also a real advantage here, emphasizes Alexander Friese
“From our desk, we can see what is displayed on each individual Peakboard at any time without having to be on site. ”
Even beyond assembly and logistics, an Andon board now provides insight: In the entrance area, a monitor provides real-time information on the plant's energy situation. The data comes directly from the plant SPS and shows at a glance the self-generation of electricity, the degree of self-sufficiency and the contribution to CO₂ reduction.
Expansion of applications and new areas of application
It is planned to expand the dashboards to include key figures such as weekly and monthly values, goal achievement and quality indicators. A shop floor board in the meeting room is also being planned, which presents plan/actual figures, variances, capacities and personnel deployment at a glance. In addition, there are suggestions from the staff to visualize information about the canteen (e.g. menu plans).
Tip for companies planning to introduce Andon Boards
“The be-all and end-all when introducing Andon boards based on Peakboard is a stably defined process. Only when the process, schedule, roles, escalation paths and data responsibilities are clear is the connection worthwhile. Otherwise, there is nothing reliable to visualize. Static Excel lists or manual exports don't help here: Without real-time, ads quickly lose their significance and acceptance. Clean interfaces to the source systems are necessary. In short: Process and data access first, then visualization. In terms of design, almost anything is then possible with Peakboard and the benefits in the area can actually be realized. ”
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