Location: 90587 Obermichelbach, Germany · Industry: Mechanical engineering, metalworking, precision parts, plant construction · Products: Precision roller bearings, special bearings, guide rollers, metal components and mechanical engineering precision parts · ERP: Alphaplan · Website: https://www.interprecise.de/ · S4P modules: 4AVO, 4APS, 4BDE
Initial situation
The manufacture of precision roller bearings at INTERPRECISE Donath GmbH, with around 100 employees, demands exact planning and coordination of sophisticated machining steps. With the ERP system Alphaplan and its connection to S4P solutions, work preparation, fine planning and shop-floor data collection are integrated end-to-end. Guide rollers, special bearings and metal components with tight tolerances require precise coordination of turning, grinding and assembly processes as well as reliable documentation of all manufacturing steps.
Challenge
Complex manufacturing processes with high accuracy requirements led to significant planning effort. A continuous link between work preparation, production planning and shop-floor feedback was missing. Bottlenecks and capacity utilisation were difficult to identify in real time, which made reliable delivery commitments to customers challenging. Manual maintenance of routings and planning data was time-consuming and error-prone; end-to-end digitalisation from order receipt to manufacturing feedback was therefore urgently needed.
Solution
Together with S4P, the ERP system Alphaplan was extended with the following modules: 4AVO for work preparation, 4APS for digital production planning in real time and 4BDE for shop-floor data collection. Work preparation provides structured preparation of manufacturing orders; the APS system enables graphical fine planning with bottleneck detection; and the BDE terminals capture order times, good and scrap quantities directly on the shop floor. All modules are bidirectionally connected to Alphaplan so that order and master data are synchronised automatically.
Results and benefits
Through end-to-end digitalisation of planning and feedback, INTERPRECISE Donath GmbH has significantly increased transparency across the entire manufacturing process. Realistic fine planning improves on-time delivery, while real-time operating data enables rapid response to deviations. Planning-reliable order confirmations to customers are now possible, manual entry effort has been reduced and a solid data basis for post-calculation and continuous improvement of precision manufacturing has been established.