+8% OEE thanks to digital production control software: Eugen Wexler relies on authentig

The demands placed on plastics processing in the automotive industry are constantly increasing: the highest quality standards, growing cost pressures and, at the same time, the need to be able to react flexibly and quickly to deviations.

Eugen Wexler GmbH, one of the largest medium-sized automotive suppliers in Germany, has risen to precisely meet these challenges – and, with ENGEL MES authentig, a production control software solution, the company has taken a decisive step towards digitalised, transparent production.

Eugen Wexler GmbH, based in Lauf an der Pegnitz, is a third-generation, family owned business. With around 1,500 employees, a turnover of 150 million euros and production sites in Europe and North America, the company develops and manufactures high-quality plastic components for interiors and exteriors – from pillar trims and boot liners to technical exterior assemblies.

The high degree of automation, complex processes such as 1K and 2K injection moulding, laminating, fabric overmoulding, painting and foaming, as well as the requirement for one-piece flow production, demand stable, transparent process management.

Before the introduction of the production control software authentig, this was precisely where the central challenge lay:

• Production and process data were documented manually

• Analyses were carried out with a time lag using Excel

• Key figures were only available to management at the end of the month

• Deviations could only be addressed reactively, not proactively

“We could really only react – but not act in real time,” says Jürgen Klein of Eugen Wexler GmbH, describing the initial situation.

With the introduction of the ENGEL MES authentig software, production control and order management at Eugen Wexler have been systematically digitised. The aim was to create a consistent, transparent and up-to-date database for all stakeholders, from the shop floor right up to management.

At the heart of the software solution is the online, real time collection of machine and process data. This enables immediate comparisons between target and actual values and allows deviations to be identified straight away.

Another key feature is real-time production monitoring: large screens in the production area display key performance indicators, cycle time deviations and faults directly where they occur. Staff can immediately see if processes deviate from the target and can take immediate corrective action.

Other key features of the authentig MES software:

• Digital production orders with live progress display

• A valid, approved data set for stable processes

• Integration of ERP data as the basis for setup and part data records

• Planning module, KPI reporting and key performance indicator analyser

• Reduction of paper-based documentation to a minimum

The effects of implementing authentig’s production control software became apparent very quickly at Eugen Wexler, both operationally and strategically.

• Significantly reduced cycle time deviations

• Faster response to disruptions

• Greater process stability through clear data sets

• Active employee involvement through transparent key performance indicators

The development of OEE in the large-scale machinery sector is particularly impressive: within just two months, OEE was increased from 81.3% to 88%.

Clear evidence of how significantly real-time transparency and digital, software-based production control can influence efficiency.

For Eugen Wexler, authentig is more than just an MES system. It is a strategic tool for securing competitiveness.

Key benefits for securing competitiveness:

• Greater cost-effectiveness

• Comparability across sites

• Scalability for international plants

• Solid foundation for further digitalisation steps