Burgsmüller – real-time fine planning and automation with FELIOS|FLS (4APS), FELIOS|PRO (4PRO) on SAP ERP

Location: 37574 Einbeck, Germany · Industry: Tooling, metalworking, thread technology, mechanical engineering · Products: Screw elements, threaded spindles, gears, special threads and components for extrusion machines · ERP: SAP ERP · Website: https://www.burgsmueller.de/de/ · S4P modules: FELIOS|FLS powered by 4APS, FELIOS|PRO powered by 4PRO

Initial situation

Production at Burgsmüller GmbH is characterised by complex workflows, high variant diversity and demanding manufacturing conditions in mechanical machining. Specialised suppliers are also integrated into the value chain. In this environment, the need for continuous real-time data from production is growing, to assess states, progress and deviations quickly and reliably.

Challenge

In the course of constructing a new factory at Burgsmüller, real-time control and automation also became relevant topics. Without sufficient transparency, it is difficult to reliably monitor manufacturing processes, detect disruptions early and make well-founded decisions. In a complex production environment with high quality requirements, this demands a digital connection between work preparation, planning, production and data collection – in close integration with the existing ERP system SAP ERP.

Solution

Alongside the day-current planning system FELIOS|APS, a real-time fine planning system was required, and FELIOS|FLS powered by 4APS was selected. Particularly important for Burgsmüller is the dynamic setup optimisation in FELIOS|FLS, as production was simultaneously converted to a container-based workflow. FELIOS|PRO powered by 4PRO was introduced to uniquely identify containers, manage storage locations, and provide suppliers with unique container numbers on SAP delivery notes – enabling traceability for end-to-end container-based value creation. Simultaneously, two DMG lathes were equipped with a KUKA robot and a roller conveyor system as an autonomous manufacturing cell by KraussMaffei Automation. S4P was commissioned to handle control, automation and networking of the cell.

Results and benefits

The closed control loop between planning and execution produces a reliable data basis for production control and enables continuous improvement. This allows processes to be planned, controlled and evaluated with greater transparency. Faster responses to deviations provide an important foundation for more efficient workflows, higher process reliability and sustained production improvements.