On its way to paperless production

GAPTEQ replaces handwritten documentation, provides an up-to-date overview of production operations and evaluates networked production information.

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The client

Pyrus Panels develops and manufactures the high-performance material lisocore® and other materials for modern lightweight construction.

The project

Digitisation and automation of production control

For modern production control, innovative manufacturer Pyrus Panels has introduced GAPTEQ in conjunction with Power BI. This customised solution brings transparency to daily production operations and paves the way for paperless manufacturing.

Highlights

Simple reporting of manufacturing data from production

Relieving machine operators of the burden of handwritten documentation

Diverse evaluation of networked production information

Daily monitoring of production operations

Mapping of individual processes and manufacturing requirements

Automated production report

Gradual expansion of production KPIs to performance

Challenge

Pyrus Panels is a forward-looking company in the wood-based materials industry. When it comes to its internal business and production processes, this innovative company is firmly committed to digitalisation and automation.

In the area of production control, however, the existing merchandise management system had reached its limits. Movement data and information from the ongoing manufacturing process had to be reported to production management by hand or in various Excel lists. This was time-consuming, confusing and lacked a central overview. Pyrus Panels was therefore looking for a cloud solution that could be implemented quickly, enabled easy documentation of progress in the manufacturing process and, above all, digitised the reports from machine operators to the production manager.

Solution

Pyrus Panels found the right solution with the low-code platform GAPTEQ. With the web interface for SQL databases, the documentation could be individually implemented as part of the manufacturing process. A GAPTEQ consultant supported the responsible project manager at Pyrus Panels in setting up the required databases and connecting the merchandise management system as a data source. After completing GAPTEQ training, the project manager at Pyrus Panels was then able to expand the application himself.

In the easy-to-use GAPTEQ web environment, machine operators can now enter their production data themselves. Information on quantities produced per order or malfunctions is reported directly from production and is now also available to the production manager at any time in a centralised location. In future expansion stages, the solution could also map the processing of ordered or stored materials with production and batch numbers, for example. As a purely browser-based application, GAPTEQ does not require any local installation, and machine operators do not need access to other office systems to enter their data.

GAPTEQ also forwards the production data to a dashboard in Power BI, which supports a wide range of evaluations and clear diagrams. A key added value here is the linking and combined analysis of information that was previously only available separately in individual Excel sheets or on paper.

Result

Instead of reporting production progress by hand or indirectly via employees using local office programmes, machine operators now report directly from the factory floor. This saves a lot of time and avoids transmission errors. At the same time, the information is transmitted in a much more detailed and structured manner.

In a fully automated report in Power BI, the production manager has an up-to-date overview of all manufacturing data. Thanks to the networked information in the BI system, even spontaneous questions can be clarified much more quickly. Evaluations that previously had to be laboriously researched are now available at the touch of a button.

It is important for Pyrus Panels that the new input and analysis platform is flexibly scalable. The monitoring of production operations and production control using meaningful KPIs is to be continuously expanded. The next step is to connect quality assurance. The modern platform is open in all directions. In GAPTEQ, any number of additional data sources can be integrated or input options defined in order to map new key figures, reports and graphics in Power BI as required.

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