A number of factors combined have prompted the move to paperless production. Over recent years enquiries for customised products have increased. In addition to this, Doka is on the path to global expansion. Both these have resulted in a sharp rise in more complex and a greater variety of parts in production. Demands to achieve greater flexibility and to maximise efficiency in the manufacturing process have grown louder. Managers have taken note of these.
In 2021, a start was made to change over and process work orders completely using a new digital solution. After tests in two production units were successful, the rollout for the project was started in other areas of production. The move towards paperless production has created even greater advantages for Doka in everyday production. Digitalisation helps to optimise processes more extensively. Our employees are also delighted, as many tasks are now simpler, clearer and more flexible.
“Through the digitalisation of manufacturing plans and wage slips, we save around 2.5 tonnes of paper a year and cut out the need to transport printouts of plans and production drawings from our factory in Amstetten to the factory in St. Martin.”
Faster! Our colleagues in production are impressed by the speed with which they can exchange information and data. The secret of this success is single point of information. And that saves valuable time. Because work orders arrive digitally, employees receive all the documents they need on their device and therefore have access to the relevant information . With this in mind, 90 industrial tablets, 24 touchscreen monitors (24 inch) and 11 large-screen displays have been installed in production.
More efficient! Planning and programming the machines for the Framax finish welding system and for powder coating has been digitised by deploying PLM software (Product Lifecycle Management). Thanks to a virtual 3D twin of the system, simulations are possible with the new system. A quantum leap for manufacturing! Shorter running-in time, fewer scrap parts and faster production of better parts. In addition to this, outages of up to 8,000 hours a year are reduced, because the software allows parallel operation of production and planning.
As part of the Umdasch Group, we at Doka aim to not only be economically successful, but also fulfill our ecological and social responsibilities as well as our responsibility as an employer. Therefore, we regularly set impulses within and outside our company and drive international initiatives that make our common working and living environment more sustainable.
“By going paperless, we are starting an initiative in production that benefits the environment and sustainability. Digitalisation of work orders does not only save paper: it also reduces all the things associated with it such as toner and transport costs.”
The cutting-edge powder-coating system has been in operation near the Amstetten headquarters since 2021. What can such a system achieve? Every single step of production can be optimised for sustainability, using the latest robot technology, digitalisation, automation and state-of-the-art technology. It protects the environment and people.