INDusTRy 4.0 / smART FACToRIEs


Fully AuTomATED C-pARTs mANAgEmENT The DIREKT RFID KANBAN system from Dresselhaus offers OEM manufacturers and mid-sized enterprises a smart solution for efficient and reliable C-parts management.


automated industrial manufacturing processes. Flexible production lines that can quickly respond to changes are decisive for the competitiveness of an enterprise. A missing bolt can literally bring the production process to a standstill. such a C-part is small, inconspicuous, inexpensive and yet indispensable. Because if it is not available at the right time in the process, this causes delays and unnecessary costs. In order to ensure reliable processes the required quantities of C-parts should therefore always be available, when and where they are needed for production. An efficient supply chain with fully automated processes minimises significant process costs due to frequent ordering, therefore securing the company’s market position.


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REDuCTION OF INvENTORIEs AND COsTs A successful method of ensuring the supply of C- parts for production solely on the basis of the actual material requirements at the point where they are needed (i.e. using a pull instead of push principle) is Kanban (Japanese for “signboard”). The goal is the cost-optimised control of the value creation chain at every production stage. Invented in 1947 by the Toyota motor Corporation, the Kanban system also became widespread in Europe and the usA in the seventies. Decentralised procurement of the required production quantities throughout the value creation chain makes it possible to reduce local inventories of primary and intermediate products. This eliminates central purchase planning and extensive stockpiling. production departments are responsible for their own supply, which gives them the versatility to respond quickly to short-term changes. When installing a Kanban system for modern C-


parts management, many companies opt for support from an experienced partner such as Joseph Dresselhaus & Co. in Herford. such partners must be able to do more than just supply DIN and standard parts. They also have to fill orders for a diverse range of products, including custom parts and specially engineered parts, as


n the age of Industry 4.0 there is an increasing demand for individualised products together with the necessity for networked, fully


Dresselhaus DIREKT KANBAN – sustainable, intelligent C-parts supply for innovative enterprises


well as auxiliary and operating materials, and even ready-made bags and kits for assembly or spare parts supply. Each single product group has different logistics requirements. This underlines the importance of ensuring maximum availability of the required product – in the appropriate quantity and quality, and at the right time and place.


MODERN C-pARTs MANAgEMENT wITh RFID KANBAN “The C-parts of our customers are our A-parts,” explains Axel Türke, manager of the Industrial oEm business unit at Dresselhaus, regarding the care taken in supplying the company’s customers with C-parts. The Herford-based company, whose customers include major suppliers of the automotive industry, developed their RFID- supported DIREKT KANBAN system especially for C-parts management. The system is built on modular procurement and logistics concepts, and includes diverse product and service solutions. They control the direct supply of their customers with small parts for production by means of RFID- supported container systems. Every container motion is detected by a special software and documented in the Dresselhaus DIREKT portal (shop.dresselhaus.de). The customer therefore continuously receives information about the status of his system, including real-time shelf visualisation. This data is used for planning of the required items, periodic optimisation of inventories, and updating of statistical data. The items are dispatched and delivered to the production line just in time.


The DIREKT shelf scale automatically initiates an order in the Dresselhaus portal when the weight drops below a defined value


MODulAR sysTEM “our DIREKT RFID KANBAN system gives our customers a procurement solution in which the demand is automatically initiated by the motion sequences of the employees in production,” explains stephan pertschy, manager of the business unit smE Industry & Digital Business at Dresselhaus. Central components are special DIREKT shelves with RFID mats, DIREKT containers and DIREKT labels, which are provided to the customer. The demand is determined by means of RFID boxes for empty containers


(available in a steel or lightweight version), RFID shelf mats and RFID scanners. These devices monitor the containers on the basis of a passive RFID transponder, which transmits its data to the Dresselhaus ERp system. This means that each container automatically initiates the replenishment of supplies. If the production rate is high, with a high removal rate, this increases the frequency of replenishment. In the same manner, the supply of parts is automatically adjusted if production is reduced or interrupted. This method optimises ordering processes, prevents unnecessary stockpiling, reduces costly production areas, and lowers operating costs – without intervention on the part of the customer.


The DIREKT order button for products with an


RFID label initiates a replenishment order at the push of the button


FEwER wRONg ORDERs AND supplIER CONTACTs The Dresselhaus DIREKT KANBAN system offers numerous advantages for manufacturing enterprises. For example, production downtimes due to lack of parts are less frequent, since the production department can take care of replenishment without outside assistance. The employees of each product line are responsible for their own DIREKT shelf. The number of wrong orders and supplier contacts is also reduced, since Dresselhaus purchase the C-parts for its customers in a centralised process. In the DIREKT KANBAN system the containers, which are made of recyclable plastic, have a similar function to that of beverage cases. The empty DIREKT containers are scanned and the data is transmitted to the Dresselhaus ERp system. This initiates picking of a replenishment order and Dresselhaus delivers the containers with the required parts within the coordinated time frame. The customer can use the parts immediately, since they are delivered without packaging. This not only reduces waste within the company, but also the costs for warehousing of materials. “The use of our system has enabled some of our customers to cut their warehousing costs in half,” says pertschy. optimised freight and


seasonal delivery cycles also reduce the Co2 footprint. This makes Dresselhaus DIREKT KANBAN a sustainable and intelligent supply system for innovative enterprises.


Dresselhaus www.dresselhaus.de


FACToRy&HANDlINgsoluTIoNs | oCToBER 2021 19


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