Reduce Resource Consumption and Increase Staff Productivity
Blechwarenfabrik Limburg has 15 autonomous electric forklifts that whizz around its cutting-edge warehouse. It’s only with real-time insights and intuitive visualization that the company can manage its complex warehouse logistics to seamlessly ship 1,000 pallets of goods every single day.
“Our reporting used to be based on spreadsheets. Usually, it takes two weeks to get updated figures,” explains Daniel Jung. “Thanks to Pentaho DataOps, we can now generate more than 100 dashboards and 700 reports automatically. This empowers employees to analyze data flexibly and make fast, data-driven decisions that maximize profitability and minimize waste.”
To improve access to these new dashboards, Blechwarenfabrik Limburg has installed 60 large screens across all departments — some in individual offices, others in shared areas. “Our analytics dashboards automatically turn on and off to reduce energy consumption,” notes Daniel Jung. “They provide instant access to key data, without the need to turn on a computer or navigate reports and spreadsheets. This has a real impact on our productivity: staff in the factory can now easily see inventory levels and manage jobs flexibly. In the past, they had to ask colleagues who then needed to check with other colleagues in different departments or click through various reports.”
Business intelligence is also at the core of the company’s efforts to innovate in manufacturing. “On the factory floor, we’re adopting the Industrial Internet of Things to implement our vision of Industry 4.0,” says Daniel Jung. “Sensor data from production lines is integrated into our data warehouse, allowing us to monitor performance and increase operational efficiency.”
By combining smarter materials management and continuous energy reporting with anomaly detection, Blechwarenfabrik Limburg has successfully streamlined its operations and made them more sustainable. For example, with Pentaho DataOps, the company can now analyze real-time data streams from its energy management system. By correlating electricity consumption, compressed air usage and cooling water flow with production schedules and outputs, it can determine optimal performance metrics.
Daniel Jung explains: “The analytics solution knows exactly when each piece of equipment is needed and can determine when machines such as high-energy induction furnaces could be turned off. Automation based on these data insights reduces energy usage along the entire production line. Similarly, the monitoring of our compressed air systems enables us to identify even small leaks almost immediately, so we can react quickly and minimize the waste of valuable resources.”
These data-driven sustainability improvements have been recognized. In 2020, Blechwarenfabrik Limburg was awarded the German Environmental Prize which was presented by the German Federal President.
“We strive for continuous improvement,” confirms Daniel Jung. “Data analytics and automation have facilitated substantially lower energy and resource usage, saving us about half a million Euros per year.”
Self-service reporting has helped Blechwarenfabrik Limburg improve sales and customer service, too. “Our sales team can instantly get the latest reports including margins, prices and order volumes for every customer,” says Daniel Jung. “Customers automatically receive notifications about all important decisions, including supporting documents such as CO2 certificates.”
Finally, the data warehouse can even be used as backup for operational systems, as it includes the source data of all connected business applications. This configuration improves the company’s business continuity and reduces risk by limiting the potential impact of IT issues across the entire system landscape.
Daniel Jung concludes: “Pentaho DataOps saves time and increases the efficiency of our sales team, while also increasing value for our customers.”