Context
Patelec Group has manufactured electrical cables and power cords since the 1950s, with vertically integrated production. Its range runs from copper wire to customised cordsets.
Challenge
- Complex coordination. The product mix required precise coordination and scheduling across many production steps.
- Late detection. Without real-time data, bottlenecks were found late.
- Inconsistent quality. Without integrated monitoring, quality was hard to keep consistent across diverse manufacturing stages.
Architecture
- Metalya APS: production planned against available resources and demand.
- Metalya Core: activities and results collected in real time.
- Quality & Process Control: quality checks with defect detection and corrective action.
- Metalya Connect: data collected from machines and sensors.
Implementation
Planning, execution and quality were brought onto one production model, so the digital plan and real shop-floor progress refer to the same orders and resources.
Result
- Scheduling is coordinated with real progress.
- Real-time activity data surfaces bottlenecks sooner.
- Quality checks are integrated with production.
- Management decides on current data.
Evidence
The published case study reports shorter cycle times and lower defect rates. These figures are awaiting customer approval for this site.