Digital Window of Opportunity – The Story of Transformation at DOVISTA Polska

DIP – The Platform That Drives Digital Transformation

DIP – what does it stand for? A great deal – functionality, capabilities, and benefits. This solution for manufacturing companies not only facilitates the daily operation of the factory but also forms an excellent base for development. So, what exactly is DIP and how does it work? Read on and explore how this platform can be your first step towards Digital Transformation.

Production Planning and Scheduling in the Food, Pharmaceutical, Cosmetic, and Chemical Industries. Specifics and Challenges.

Planning and scheduling are the basics of efficient and effective production in any production facility. However, the same principles do not apply everywhere, as individual industries have their own characteristics, needs, and guidelines. Taking these into account already at the planning stage makes the plan feasible, and clearly, only such plans are worth executing. What challenges do the food, pharmaceutical, cosmetics, and chemical industries face while preparing plans and schedules? What role does APS play in overcoming them?

Technical Cost of Production (TKW): Knowledge Compendium for the Industry

Untangling the impossible: How ESB cuts through the Gordian knot of system communication.

Imagine that all decisions, plans and processes, and even individual actions in your company are based on the same, consistent data. Single source of truth – this is the ideal that many manufacturing companies strive for. How to achieve it in an environment where a huge number of applications are running in parallel, each with its own requirements? With help comes the ESB, or data bus, which is a kind of bridge between distributed systems.

Is machine monitoring already MES?

Machine monitoring or whole machine monitoring systems are solutions that allow automatic collection of data from machines in production IT systems. Their manufacturers promise quick connection and quick benefits. But can machine monitoring systems be an alternative to MES-class systems? And are they the right choice in the perspective of full digitization of the enterprise?

Multiple industries

Case study

MES/MOM

It began with a specific need and culminated in a model factory.

Driven by the need to integrate many dispersed systems across various locations, the DOVISTA company, one of the fenestration industry leaders, embarked on a path of Digital Transformation. Increasingly complex orders and the demand for product customization led to the implementation of further solutions that changed the way factories within the “DOVISTA Wędkowy” operate.

Together with the ImFactory team, DOVISTA created an integrated environment based on the solutions by AVEVA and SAP, connecting the world of machines with the level of business and operations. Key technologies included the AVEVA MES, AVEVA Enterprise Integration ESB, and dedicated applications from ImFactory that support operators in their daily work.

The elimination of paper forms, automatic generation of machine files, improved quality management, and fast access to current data – these are only a few effects of the transformation. Presently, the system processes over a million messages and handles over one and a half million production tasks every month! However, the transformation isn’t only about numbers. What lies behind DOVISTA’s success? A process built on trust, collaboration, and the engagement of people – from management to engineers and operators. And, above all, a clear understanding of where the essence of Digital Transformation truly lies.

About the Company

Industry: Fenestration

DOVISTA Polska Sp. z o.o. is a group of factories in Wędkowy, which, together with the plant in Lithuania and Dobroplast Factory in Zambrów, comprise the DOVISTA Group and use solutions developed with ImFactory. DOVISTA factories manufacture high-quality windows and doors under the Rationel and VELFAC brands. Production is based on custom orders created for individual customers. The company places strong emphasis on development and investment in new technologies, and their powder-coating factory launched in 2016 is one of the most modern facilities of this type in Europe.

Goals

Reduce paper forms and manual labor – automate the execution and monitoring processes.
Supply workstations with current data on the production plan, manufacturing technology, and machining individual elements.
Improve the quality and timeliness of order execution.
Reduce the time needed for production setup and reporting.

Solutions

AVEVA MES system for production management
AVEVA System Platform and AVEVA Historian
AVEVA Enterprise Integration ESB
ImFactory Bundle
ImFactory ImGo
Dedicated applications developed by ImFactory and DOVISTA

System Scale

> 170 machines connected to the system
> 600 workstations of various types
> 1 500 000 production tasks executed each month
> 350 tablets operating the system
> 200 various large-format displays
> 1 200 000 messages exchanged through the data bus each month

Effects / Benefits

Fast access to production data, improving operational efficiency.
Better production planning and implementation through order execution tracking and real-time operation status.
Improved integration and communication between systems.
~85% reduction in paper usage, resulting in cost savings and environmental benefits.
Easier work for operators through data visualizations and automatic machine file generation.
Improved management of the quality and complaint process.
Greater flexibility in custom production.