Production logistics: data-driven and efficient

Fast processes through digital procedures

Intralogistics in a modern car factory increasingly uses driverless transport systems (DTS) to transport parts and components between the storage areas and the assembly area. The assembly stations are supplied with shopping baskets with defined places,
which are filled by the commissioners in a picking zone. The assembly workers then find the required component in the designated compartment. This allows a very high level of variance to be combined with efficient assembly processes.

“Digital processes for picking components and filling shopping baskets speed up processes significantly,” explains Thorsten Bender, branch manager at Rhenus Automotive. One well-known process is
“pick-by-light”. LED displays on storage compartments show the pickers exactly where the parts to be picked are located. At the same time, the desired quantity appears on displays. This procedure – if used correctly – reduces the error rate to almost zero, and after a training, the system is easy to use.

Training with our own training facility

“New staff can also be trained very quickly,” adds Timo Schiek. “This significantly increases the productivity and efficiency of the warehouse.” A training team of several experienced specialists usually takes care of the onboarding, which at Rhenus usually begins with a comprehensive week of training. The new employees are given intensive support for five days before they are allowed to work independently.

To ensure that employees of different nationalities understand everything correctly, the training courses are offered in several languages and rely heavily on visual teaching methods. An integral part of the training is practical exercise in a specially set up pick-bylight system. Here, participants can spend several hours experiencing and trying out in practice how the processes interact and how they have to pick, grasp and remove quickly and without errors. In the first few days after the training week, they also receive support from experienced colleagues. In this way, Rhenus ensures that all new employees fully understand the processes and can take on their tasks with the appropriate qualifications.

Real-time data is the biggest success factor

One hurdle in using logistics systems is the necessary data transparency. Basically, every factory has its own data collection, especially
on the shop floor. “We have to adapt our data and applications precisely to the OEM‘s system,” says Rhenus manager Schiek. “Despite this effort, it is important to use our own solutions in order to be able to monitor the processes better.” Rhenus therefore developed uniform applications – supported by Staufen – that combine all the data from both companies. This harmonization of the data and systems is a key success factor.

The integration of the logistics service provider and suppliers into the customer system enables the identification of weak points in both the Rhenus and OEM systems. “Another success factor here is data-driven deviation management,” says Thorsten Bender from Rhenus Automotive. It focuses on working with real-time data to quickly solve problems and respond to errors within minutes. The data is compared in Shop Floor Management using dashboards, on a daily base or several times per shift. This means that everyone involved always has the same level of information in order to be able to respond effectively to deviations.

A common vision at all levels as the key to performance

Since streamlining the organization is important for consistent deviation management with real-time data, Rhenus relies on a so-called two-hour board. Instead of someone going around with paper and pencil, Rhenus has developed a digital solution. The tool enables to forward data to the quality department at short intervals for the operational logistics and the quality department and to take immediate countermeasures. “This is crucial for shortening response times,” says Rhenus manager Bender. “This way, we don‘t just talk about yesterday‘s mistakes, but also avoid mistakes of the following hours.”

Rhenus‘s high level of process understanding in intralogistics, combined with Staufen‘s expertise in Operational Excellence, the organizational development and data analytics, ensures a high impact on performance right from the start of a new logistics mandate. “Rhenus thus achieves increased efficiency through fast processes, precise material supply, and a significant reduction in the error rate,” says Staufen partner and automotive expert Alexander Wagner. “Effective communication within Rhenus and with its customers, the seamless integration of logistics data and the methodical resolution of errors and problems with the utmost consistency are crucial here.” Thomas Bernhardt, COO of Rhenus Automotive, adds: “Both require a practice-oriented combination of consulting, training and coaching – the perfect job for Staufen.”

About Rhenus Automotive

The Rhenus Group is a global high-tech service provider in the field of assembly and logistics with an annual turnover of 7 billion euros. Rhenus Automotive operates over 50 locations worldwide and employs around 10,000 people. The company offers automobile manufacturers intelligent and efficient system solutions in the areas of assembly and logistics.

Complex assembly and logistics processes are analyzed and optimized using customized solutions for procurement, production, and distribution. The assembly processes range from simple manual activities to the complete assembly of drive components such as engines, transmissions, axles, chassis, and other parts.

Planning, financing, construction, operation, maintenance, and continuous improvement of assembly lines are core competencies in the field of intelligent assembly. The logistics solutions include goods receipt, warehouse management, and production supply.

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