Worldwide roll-out of the mobile SAP solutions

Tanks with transparency – For quality assurance and traceability of individual components in the production of vehicle tanks, the automotive supplier Kautex Textron relies on the mobile data acquisition FlexMobile from Flexus.

After introducing the mobile solutions, we were able to save the distances travelled, as well as time and costs, and
increase reliability at the same time.”

Jörg Wojtun
Head of Production Logistics
Kautex Textron
GmbH & Co. KG
Bonn location

Extreme temperatures and severe vibrations: When it comes down to it, a car’s fuel tank has to withstand the greatest loads. Vehicle tanks are safety-relevant and their production is therefore subject to strict requirements. Kautex Textron is one of the world market leaders for tank systems, which the Bonn-based company manufactures in 16 countries. Among other things, in order to be able to show a face to the customer within logistics, Kautex Textron decided in 2010 to standardize and simplify logistics processes worldwide. All movements between goods receipt, production supply, production confirmation, picking and goods issue should be documented, checked and visualized. At the same time one wanted the dialogues in the individual simplify process phases. The search was for an easy-to-use solution that could be used directly with the merchandise management system SAP communicates and accompanies every single step of the components up to the fully assembled tank system. Additional poka yoke checks should make the process totally safe.

Configure via drag & drop

driver kautex

After a thorough selection process, Kautex Textron opted for the SAP add-on FlexMobile (SAP® ECC 6.0) from Flexus. “As an SAP partner, Flexus offers us direct integration of the application into our ERP system,” explains Christine Müller, who designs the global processes in logistics at Kautex Textron together with Ria Classen.

The existing ones provided another argument
more than 200 applications or templates that can be used immediately, which the customer can
modular principle can be managed.

There are extensive applications for warehousing, internal transport, production and order picking
accessible. The mobile transactions are standardized. The dialogs can be arranged with the help of a graphical layout
Assemble Designers yourself using drag & drop and use them for different devices. “The solution is designed
that the global rollout is carried out independently of Flexus by our own IT staff can,” emphasizes Christine Müller. The Flexus specialists only have to lend a hand in the case of individual changes within the logistical processes. “This is the case, for example, when customers come to us with new requirements and the processes have to be changed for this,” explains Christine Müller.

The Belgian production plant in Tessenderlo started in 2010. 16 other locations followed in Spain, Brazil, England, the Czech Republic, Germany and Romania. “We are now working there with standardized processes, which our globally active customers really appreciate,” says Christine Müller. More than 400 employees in the various storage and production areas now have access to the Flexus application. More than 130 mobile handhelds are used for this.

Every logistic unit traceable

The process of mobile data collection begins in the incoming goods warehouse. Every product that arrives there is provided with a barcode label. From this point on, the consignment unit is considered a so-called “handling unit”, HU for short, which can now be tracked individually throughout the logistics process. After the goods have been received, the HU is stored. To do this, the employee calls up the application intended for storage on their mobile device and scans the barcode. From here it goes either completely or in partial quantities to the respective site’s own production facility or – for example in the case of small parts – to the upstream supermarket. As soon as a new logistic unit is created, e.g. B. at the end of the production process, a new HU is created with its own label including barcodes. These HUs can also be processed using the Flexus application in further process steps such as picking.

Goods receipt Scan Kautex

Reacting on site saves travel costs

Irrespective of the process step, the data from the HUs is compared with the ERP system via FlexMobile immediately after it has been recorded, so that the current processing status is queried in the SAP system. Should there be any discrepancies
enter or the recorded data is not complete, the process is immediately aborted and a warning message
appears on the scanner. “The employee can now see right away that something is missing and can react immediately with the help of FlexMobile,” says Jörg Wojtun, who is responsible for logistics at the Bonn location. Without mobile data acquisition, a stationary PC used to have to be used in such cases. “After introducing FlexMobile, we were able to save on the distances covered, as well as time and money, and at the same time increase reliability,” confirms Jörg Wojtun.

Further savings potential

FlexMobile has proven itself at Kautex Textron since 2011 and the roll-out is scheduled to take place in the next few years
be continued. But the project is far from finished. Finally, FlexMobile there is still further potential for savings and improvements, such as carrying out inventories. Instead of with paper counting lists, the annual full inventory is also to be carried out in the future with the help of the mobile terminals. Christine Müller has already designed the corresponding process.

Background poka-yoke

Scanning process Kautex

The Japanese expression “Poka Yoke” (“avoid mistakes”)
designates one consisting of several elements
Principle that technical precautions for immediate
includes error detection and prevention. poka yoke
is based on the realization that no man and also no
System is able to completely unintentional errors
to avoid.

Using Poka Yoke is mostly done through simple and effective Systems ensure that mistakes in the manufacturing process do not lead to defects in the end product. An example of poka yoke in everyday life is a gas cap that is connected to the vehicle with a rubber band.

Logo reference customer Kautex

Kautex Textron is a global system supplier for the automotive and packaging industry with headquarters in Bonn. This employs in 16 countries
companies specializing in tank systems have 6,500 employees who generated sales of around 2.1 billion US dollars in 2015. In order to
Kautex Textron is one of the 100 top-selling automotive suppliers
worldwide. The company, founded in 1935, has been dealing with blow molding machines and the manufacture of hollow plastic objects since 1949. In 1964, Kautex presented the first plastic tank for passenger cars. Since 1996 the company has been part of the multi-industrial group Textron Inc. with a total of 34,000 employees and headquarters in Rhode Island, USA.