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 a continuous process optimization, Engelmann decided to fundamentally modernize its production control in order to further increase efficiency and delivery reliability.
From Production Planning to Pull System
Before the introduction of the IKS e-Kanban system from manufactus, Engelmann did not have a Kanban system. Production was controlled according to a classic push principle, in which all pre-assembly modules were planned separately in production planning. This approach repeatedly led to problems: there were always significant delays in the final device production because required pre-assembly modules were not completed in time. The lack of synchronization between the production stages was the main reason to look for a new, more agile control method.
“The clear goal was to switch to a continuous pull system, thanks to the practical examples shown to us by our external consultant,”
says Mr. Zeller, Head of Production, describing the situation at the time and the charted course for the future.
Selection and Implementation of IKS
The decision for manufactus and the IKS system was initiated by an external specialist for process optimization, who accompanied the redesign of the entire supply chain processes at Engelmann.
The introduction was remarkably fast:
• Quick implementation: The first Kanban control loops for production were implemented and functional just a few weeks after the system was made available.
• Gradual expansion: Over the following months, the system was gradually expanded to include more and more articles.
• Process expansion: Later, IKS was used not only for controlling production but also for controlling relocation processes between warehouse and production.
Success Factors in the Introduction
“The direct connection of IKS to the company’s ERP system is one of the biggest advantages, but it also posed the biggest challenge. Entries in IKS immediately trigger material movements and postings in the ERP system,”
says Mr. Zeller. The most critical point was avoiding incorrect postings. Especially when creating, testing, or changing Kanban control loops, errors occurred initially. A small oversight, such as accidentally fully reporting a Kanban, had major consequences – for example, a production order was booked in the ERP system, which led to incorrect inventory levels.
The solution lay in developing a deep system understanding and establishing a process that requires the highest concentration.
The team learned to interrupt the communication between IKS and ERP at exactly the right time and to safely reactivate it after the changes were completed.
Current Application Area and Scope
Engelmann now uses the IKS system comprehensively and in all three variants:
• Production Kanban: Control of production orders.
• Relocation Kanban: Control of the material flow from the warehouse to production.
• Supplier Kanban: Connection of external suppliers.
“While the introduction of production and relocation Kanban can be described as relatively simple, connecting external suppliers to a supplier Kanban posed a greater challenge. Many suppliers are not so easily convinced that Kanban also brings many advantages to them, such as less fluctuating demands, even deliveries, and a stronger customer loyalty,”
Klaus Zeller describes the situation at the time. Nevertheless, Engelmann was able to successfully overcome this hurdle through continuous training and the commitment of the team.
Achieved Improvements and Successes
“Through the introduction of the IKS e-Kanban system, Engelmann was able to establish an autonomous production control system, which has led to significant time savings through direct ERP connection and simplified, error-free internal logistics,”
Mr. Zeller summarizes the result after the successful introduction 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.”