New Standards in the Door Industry

Wassermann helps JELD-WEN realize a new manufacturing and delivery concept

Apart from the innovative production and stock control system, the new platform warehouse at the Oettingen, Bavaria site is instrumental for the 5plus concept.
(PresseBox) ( Munich, )
Employing its new, dynamic production and delivery concept, 5plus, JELD-WEN Germany has managed to reduce delivery times significantly for an extensive assortment of interior doors and matching wooden door frames. At the same time, the company succeeded in cutting down on cycle times by 12 percent and on stock levels both in production and of finished products by more than 30 percent, resulting in significantly lower capital expenditure. Three products from Wassermann formed the basis for implementing this concept: wayRTS (Real Time Simulation), the flexible real-time production planning system, wayMES (Enterprise Frontend), the innovative production control system, and wayKPI (Performance Monitor), enabling to monitor and assess the supply chain in an effective way.

In its desire to reorganize he production at its two manufacturing sites in Mittweida/Saxony and Oettingen/Bavaria, JELD-WEN Germany had set an ambitious goal for itself: Around three quarters of the Moralt and Wirus brands assortment, i. e., more than 10,000 interior doors and 15,000 matching door frames, were to be delivered to customers within five days of order release. 90 percent of the consignments were to be carried out within 15 days instead of the previous 25 days-with thousands of additional configuration options.

Obstacles of many kinds were in conflict with this goal, including intersecting material flows as well as inadequate synchronization and intermediate storage in production. Added to that, there were production control shortcomings, particularly in capacity planning and rework of defects. And the information flows also lacked adequate transparency.

Complete success with Wassermann way

JELD-WEN decided to work with Wassermann in order to build a new basis for its production and delivery Mittweida und Oettingen. In all, their joint project comprised a value stream analysis, design and implementation of a process driven organization at JELD-WEN as well as complementing the existing ERP system with SCM functionality. For production planning purposes, Wassermann provided its customer with the Advanced Planning & Scheduling (APS) Software, wayRTS. It enables JELD-WEN to plan all its value-added steps across production sites in real time. wayRTS creates ideal conditions for tapping the supply chain's full economic potentials by providing the planning process with visibility and offering easy intervention options with planning support automatable to any extent desired.

In February of 2009, live operations were successfully started - first in Oettingen, afterwards in Mittweida. Work in progress inventories decreased by 31 percent, throughput times were reduced by 12,5 percent. Stock levels of finished products dropped by 37 percent - resulting in a corresponding monetary benefit. "Without Wassermann, we would never have been able to realize our dynamic production and delivery concept, 5plus," Bernd Kressmann, managing director of JELD-WEN Germany, comments. "Just with the help of the achieved inventory reductions, the project has earned its cost several times within one year of the project kick-off."

Rapid information flow and daily updated indicators

The Wassermann solution at JELD-WEN also includes Manufacturing Execution functionality aimed at promoting the value generation process's overall responsiveness. wayMES enables rapid information interchange between the company's departments and those in charge of planning. The software helps retrieve the queue of work approved for feasibility by process management. The departments are given notice of all the individual process steps' key deadlines along with the operation queue. Moreover, wayMES acts as central tool for feedback information such as completion notifications or departments' actual time recordings or free capacity offers.

In order to be able to monitor the process improvements achieved by the new production system on an ongoing basis, JELD-WEN will also be implementing the performance monitor, wayKPI, from Wassermann. This controlling instrument will continuously provide JELD-WEN's management with up-to-date, meaningful logistics indicators and so efficiently help them perform their operative company administration duties.

For more information, please contact Wassermann or visit www.wassermann.de.

About JELD-WEN Door Solutions

JELD-WEN Door Solutions is part of the JELD-WEN group, the world's largest supplier of doors and windows. A leading company group in the field of manufacturing and distributing doors in Europe, JELD-WEN Door Solutions offers a comprehensive, country-specific portfolio of interior doors and front doors - from standard products for do-it-yourself enthusiasts to premium fashion and designer doors through to technical doors for the most exacting requirements, e. g., for fire, smoke, noise, or radiation protection or object security. In Germany, JELD-WEN employs a workforce of more than 900 at four locations; across Europe, JELD-WEN Door Solutions has 14 manufacturing and 16 sales locations for doors and door frames with a total of more than 4000 employees.

www.jeld-wen.biz
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