Tristar Steel opted for digitalization of its production processes by implementing the KFactory® platform
Tristar Steel, part of the Akçelik Group, a globally renowned innovative company specialising in the production of hard chrome steel bars and linear shafts, has opted for the digitalisation of its production processes by implementing the KFactory® platform.
Prior to this initiative, the company faced significant challenges in collecting and analysing production data, which directly affected operational efficiency and decision-making.
Context:
The collection of production data at Tristar was done manually, using worksheets and disparate computer systems. This was prone to errors, delays and gave an incomplete picture of production processes. As a result, the company faced the following challenges:
■ Lack of visibility: No overall visibility on the real-time performance of production lines.
■ Incorrect data: Manual errors were affecting the accuracy of reports and analysis.
■ Delays in reporting: Reports were generated late, making it difficult to take operational decisions.
■ Difficulties in optimizing processes: Lack of accurate and up-to-date data prevents problems from being quickly identified and remedied.
■ The operational processes of quality, stock management and production order management were hampered by the lack of real-time data.
The Solution:
To overcome these challenges, Tristar Steel decided to implement the KFactory® platform. The solution was implemented on a complex production line, integrating various industrial machines. The KFactory® team worked closely with the company’s operational team to ensure a successful implementation.
“The main reasons for choosing the KFactory® solution are:
■ The need to monitor performance in real time and identify bottlenecks so that we can make quick;
■ The need to improve productivity and reduce downtime;
■ The need for improved traceability of both materials and labor;
■ The need of improving individual and group responsibilities;
■ The need for real-time data collection and analysis to optimize processes and reduce costs;
■ Flexibility and scalability;
■ Improving the efficiency, quality and competitiveness of production operations, ultimately contributing to higher profitability and increased customer portfolio.
PRODUCTION EFFICIENCY:
registered growth in the first 3 months of implementation
20%
USERS:
all operators use the platform
50
Features of the chosen solution, best practices:
■ Automated data collection: production data is collected automatically and in real time, eliminating human error and improving the accuracy of information.
■ Real-time visibility: the platform provides a clear and up-to-date picture of equipment and operator performance.
■ Advanced analytics: KFactory® Analytics enables customized reporting and data analysis to identify trends, anomalies and opportunities for improvement.
■ Integration with ERP system: the platform integrates with the Navision ERP system to take production orders and automatically transmit the collected data.
Results:
The implementation of KFactory® has had a significant impact on Tristar Steel’s operations:
■ In the first 3 months of implementation there was a 20% increase in production efficiency.
■ Now the rules and execution times for orders can be set correctly.
■ Real-time visibility on order execution status.
■ Improved data quality: the data collected is more accurate and reliable, allowing more accurate performance analysis.
Tristar Steel continues to exploit the potential of the KFactory® platform. The next project milestones include:
■ Monitor energy consumption to reduce costs and improve sustainability.
■ Carbon footprint calculation to comply with environmental regulations and demonstrate the company’s commitment to sustainability.