Paperless production
with batch size 1 in production.
In the initiative to realise a "paperless factory with batch size 1", the Tischlerei Grömmer has set new standards for digitalisation in the joinery industry in collaboration with Zentro. Following completion of the project, the company processes orders completely digitally, even for single-item production. The Zentro Go production control system implemented by Zentro facilitates the team's processes through to assembly thanks to efficient communication channels, precise individual part tracking and optimised quality management.
In line with this digital transformation, Zentro's system ensures the seamless integration of parts lists and production data with the ERP, capacity planning and machines, which is essential for maintaining high and consistent productivity in project realisation.
Paperless Factory.
"We were looking for a long time for a solution that could meet our requirements in terms of innovation, flexibility, transparency and ease of use. Zentro Go was able to fulfil our individual requirements 100%."
Konrad Grömmer
Managing Director, Tischlerei Grömmer
Increasing production efficiency through
Paperless Factory.
At the Grömmer joinery, the 'Paperless Factory' project aimed to reduce non-value-adding time expenditure by 70%, which mainly consists of administrative activities. This strategy was implemented using the software-supported Zentro Go system, which was specially designed and integrated for the management of customised production. This system combines functions for digital communication, process documentation, automated planning and quality assurance and connects seamlessly with existing IT resources, enabling significant optimisation of work processes.
After implementation, the joinery saw a considerable reduction in throughput times within the first month, which significantly strengthened its position as an innovative company in the market.
Within a year, it was possible to close the digitalisation gaps and thus build on existing services.
Efficiency
"With Zentro Go, we no longer need to search for long. Everyone knows immediately what to do."
Andrea
from the Grömmer team
Procedure
In the pre-project phase, a rough requirements analysis was carried out based on the information provided by the customer. Based on the requirements, a rough concept was drawn up and also visualised graphically to ensure maximum transparency. The rough concept served as the basis for the cost estimate and as a basis for discussion for the specification of the solution to be implemented.
A relationship of mutual trust was established even before the project began. A mix of existing and new software tools, individual programming and organisational measures were integrated into an overall solution. This holistic approach, which took into account the customer's preliminary work in all affected areas, qualified the solution as the ideal choice.
A trial operation phase lasting several weeks with a fixed end date was planned before the project was completed. On the one hand, this gave the customer the opportunity to test the solution with a broad user group after completion of the implementation work and to respond to any change requests late in the project. On the other hand, the deadline prevented potential delays.
As a result of the project, Grömmer has become the technology leader in the industry in the field of paperless production. As far as we know, this is unique for batch size 1 in the joinery trade. The use of AI as part of the solution further emphasises the company's technological leadership. The implementation of agile methods in an iterative process emphasises the innovative nature of the project.
The project also led to a reduction in paper consumption of around 90%.
Transparency
"As it is becoming increasingly difficult to find well-trained staff these days, we see our only chance in keeping the productivity of our existing staff as high as possible and organising our working methods in a very transparent and efficient manner."
Konrad Grömmer
Managing Director, Tischlerei Grömmer
Qualified personnel
Retaining qualified employees is currently one of the most important challenges for employers. The advanced solution realised in the project makes a decisive contribution to retaining key personnel and ensures sustainable job security for all qualification levels.
Employers have a responsibility to their team, especially in the face of social challenges and increasing pressure on individuals. The introduction of the new solution has reduced mental stress in the workplace and significantly reduced the risk of burnout.
In addition, this project has increased our client's operational room for manoeuvre, which both helps to secure existing jobs and facilitates the expansion of business activities.