Engelmann Sensor GmbH
Engelmann Sensor GmbH, based in Wiesloch-Baiertal, is a leading European manufacturer of heat meters, water meters, and related system solutions. The company stands for the highest quality and innovative products in measurement technology. As part of its ongoing process optimization efforts, Engelmann decided to fundamentally modernize its production control system to further increase efficiency and delivery reliability.
From Planned Scheduling to a Pull System
Before the introduction of the e-Kanban system IKS from manufactus, Engelmann did not have a Kanban system. Production was controlled according to a classic push principle, in which all pre-assembly assemblies were scheduled separately in production planning. This approach repeatedly led to problems: Significant delays in end device production occurred repeatedly because required pre-assembly assemblies were not completed on time. The lack of synchronization between the production stages was the key reason for looking for a new, more agile control method.
“Based on the practical examples presented to us by our external consultant, the clear goal was to switch to a consistent pull system,”
is how Mr. Zeller, Head of Production, describes the situation at the time and the path ahead.
Selection and Implementation of IKS
The decision to implement manufactus and the IKS system was initiated by an external process optimization specialist who supported the redesign of Engelmann’s entire supply chain processes.
The implementation was remarkably rapid:
- Rapid implementation: The first Kanban control loops for production were implemented and operational just a few weeks after the system was deployed.
- Gradual expansion: Over the following months, the system was gradually expanded to include more and more items.
- Process expansion: Later, IKS was used not only to manage production but also to manage transfer processes between the warehouse and production.
Success Factors for Implementation
“The direct connection of IKS to the company’s ERP system is one of the greatest advantages, but also posed the greatest challenge. Entries in IKS immediately trigger material movements and postings in the ERP system,”
says Mr. Zeller. The most critical issue was avoiding incorrect postings. Initially, errors occurred particularly when creating, testing, or modifying Kanban control loops. A small oversight, such as accidentally reporting a Kanban as full, had major consequences – for example, a production order was posted in the ERP system, resulting in incorrect inventory levels.
The solution lay in developing a deep understanding of the system and establishing a process that requires maximum concentration.
The team learned to interrupt communication between IKS and ERP at exactly the right time and to safely reactivate it after the changes were completed.
Current Scope and Extent
Engelmann now uses the IKS system comprehensively and in all three variants:
- Production Kanban: Control of production orders.
- Stock Transfer Kanban: Control of material flow from the warehouse to production.
- Supplier Kanban: Connection to external suppliers.
“While the implementation of production and stock transfer Kanban can be described as relatively simple, connecting external suppliers to a supplier Kanban system presented a greater challenge. Many suppliers are not so easily convinced that Kanban also brings them many advantages, such as less fluctuating demand, consistent deliveries, and stronger customer loyalty,”
Klaus Zeller describes the situation at the time. Nevertheless, thanks to continuous training and the team’s commitment, Engelmann was able to successfully overcome this hurdle.
Improvements and Successes Achieved
“By implementing the e-Kanban system (IKS), Engelmann was able to establish autonomous production control, which led to significant time savings through direct ERP integration and simplified, error-free internal logistics,”
summarizes Mr. Zeller, summarizing the results after the successful implementation and use of the manufactus e-Kanban solution, and concludes with satisfaction:
“The successful implementation of Kanban and the IKS system has not only increased efficiency but also sustainably improved Engelmann’s competitiveness in the industry.”