TROESTER – real-time shop-floor data collection with FELIOS|BDE (4BDE) and operator guidance for complex BOMs in SAP ERP

Location: 30519 Hannover, Germany · Industry: Mechanical engineering, plant engineering, extrusion, rubber industry, assembly · Products: Extrusion plants, rubber extruders, cable machines, rolling mills and plants for rubber and plastics processing · ERP: SAP ERP · Website: https://www.troester.de/de/ · S4P modules: FELIOS|BDE powered by 4BDE

Initial situation

In mechanical engineering at TROESTER GmbH & Co. KG, with around 700 employees, complex manufacturing orders, high quality requirements and the need for greater transparency in production converge. Extrusion plants, rubber extruders, cable machines and rolling mills are produced in demanding assembly and manufacturing processes. Operating data from manufacturing was to be reliably captured and integrated with the ERP system SAP to make order and operating data transparent in real time, reduce manual capture effort and evaluate manufacturing utilisation reliably. Of particular importance is the operator guidance system for complex bill-of-materials bookings in assembly.

Challenge

In mechanical engineering with complex bills of materials and long lead times, gapless shop-floor data collection was essential to reliably document manufacturing progress, times and material feedback. Without a digital BDE solution, manual feedback was error-prone and delayed. A particular challenge: assembly processes require an operator guidance system that controls the booking of complex BOMs and their components, thereby minimising assembly errors. Integration with SAP ERP had to be bidirectional and audit-proof.

Solution

To optimise manufacturing processes, TROESTER GmbH & Co. KG relies on FELIOS|BDE powered by 4BDE. Integrated with SAP ERP, a new operator guidance system is deployed specifically for assembly to handle the booking of complex bills of materials and their components. This enables end-to-end capture and evaluation of order and operating data for transparent and reliable production control.

Results and benefits

With FELIOS|BDE powered by 4BDE, TROESTER GmbH & Co. KG achieved higher transparency in manufacturing and a reliable data basis for production control. Operating data is captured reliably, utilisation and disruptions are identified early and manual capture effort was reduced – for greater efficiency and on-time delivery. The operator guidance system for complex BOM bookings reduces assembly errors and sustainably improves the quality of feedback data in SAP ERP.