Engineering Services

Competitive edge through CURRENT STATUS analysis! Analysis of your system landscape, tool inventory, machinery and current processes. We therefore offer you the very best optimisation. This increases your efficiency at the same time as making you more flexible. Individually combine additional modules for a perfectly networked factory.

The Benefits for you

• Increase process reliability through identifying weak points in the current structure
• Increase the quality of internal processes at the same time as lowering costs
• Customer-focused solution for transparent production processes
• Standardised definition of all tools, machines and existing interfaces and software systems (e.g.: CAD/CAM, ERP, MES)
• Current analysis of the existing organisation of operational workflows and planning and control processes
• Analysis of the existing machinery and internal logistics systems
• Evaluation of the current state of your company delivers qualified knowledge for process evaluation
• Customer support in your own company
• Individual project folder

Our services

Analysis of your production workflows
In carrying out a precise analysis of your inventory, your expert determines the current situation with your production. The analysis provides basic information about optimisation with regard to time, cost and quality. In the further SWOT analysis, we consider together with you the strengths, weaknesses, opportunities and threats. We then develop strategies for the long-term improvement of your processes based on the analysis. Our experts will support you in remaining competitive in the future.

Check of the existing equipment for technology standards
Do all your processing and measuring machines use state-of-the-art technology in the production process? KELCH can provide the cutting-edge technologies for your production. In many cases, an update of the machine control system would be just about enough to optimise it to the latest standard. In particular, the ability to communicate with external systems increases the process quality, because input errors are prevented. We will also guide you through and implement reasonable integration to ensure that your core competence fields are up to date.

Analysis of current situation
KELCH offers a comprehensive target concept based on a sound actual analysis of the business, organisation, planning and control processes. On this basis, all of the following project plans and the organizational structure can be carried out. However, it is process owners that should be behind the new changes. Otherwise, the implementation of the smart factory with the total redesign of the planning process will be impossible.

Recording of all tools, machines, interfaces and software systems
Our team of specialists will deal with the entire production, including all critical areas. In so doing, the hardware area, including the complete inventory of tools, machinery, measuring equipment and individual components through to the software area, including interfaces and system applications, will be assessed, analysed and recorded in a sound manner. This will give you a first impression and enable crucial conclusions to be drawn as to the workflow and process errors across departments. At the same time, KELCH will highlight fundamental initial information for further planning of optimised production.

Discovery and elimination of bottlenecks
Another important step is the identification of bottlenecks in the production process. Finally, it is not enough to optimize the machine in such a way that the output is increased whilst keeping up with the loading or unloading of the machine. Are there any manual workstations that fall behind, or the logistics concept inadequate? Our experts often reveal weak points in historically evolved structures. These can be eliminated by implementing simple measures. This helps you save time or increase your output. In both cases, we can see your company benefit from savings or higher output.

KELCH experts directly on site
The goal is to perform an analysis, stocktake and hold discussions with you in your company. This provides us with an immediate picture of your production: we see what equipment is available, and then define specific aims and the timeframe for implementation. This produces a document listing requirements and proposed implementation. At the same time, this produces a traditional requirement specification and functional specification.

Production of your project folder
Our philosophy here is "Optimisation on demand" that helps us optimise the required production workflows, and individually adapt to your situation, your requests and your requirements. You will receive an exclusive project folder that includes all relevant modules and information from the Smart Factory Services programme.

The smart team 4.0! Together we work out the perfect 4.0 solution plan to form the basis for future decisions. Tomorrow's success can
be planned today. This increases your efficiency at the same time as making you more flexible. Individually combine additional modules
for a perfectly networked factory.

The Benefits for you

• Overview of a detailed workflow plan
• Lean manufacturing approaches ensure consolidated manufacturing steps
• Value stream design is used to improve customer-orientated material and information flow
• Development of manufacturing layouts, including: tool room and tool logistics concepts
• Optimise machine equipment, for example as original equipment for new customers or as retrofit equipment with existing customers
• Tool and component storage is simplified by automatic issuing systems and the range of models is minimised
• Realistic interim targets to adhere to time schedule
• Extremely close cooperation with the customer
• Customer support in your own company
• Individual project folder

Our services

We produce a detailed workflow schedule together with you
Smart Team 4.0 will work together to create work packages showing an overview of the necessary tasks. For a better chronological overview, KELCH will employ the project management techniques such as network, WBS and Gantt chart to identify the so-called schedule lists for the project. Thus, we can guarantee a smooth workflow in the implementation process, if each team member fulfils its tasks and adheres to deadlines.

Design of production layouts
Managing the individual tools and machines as well as monitoring the entire production process chain pose a particular challenge for a Production Manager. This consistent control in production and the previously effective planning provide for better transparency. Thus, creating a tool room or tool logistics concepts is a first step towards smart factory and subsequent process optimization services.

Development of lean manufacturing and value stream workflows
The fundamental goal is to combine responsibilities within the company and to pick up the core competence from numerous previous individual competencies in the future. In so doing, the expert provides a basis for synchronizing the processes and the background of the continuous improvement process. Moreover, we will work together to create a consistent working arrangement. In short, complex processes are simplified and separated into easily controllable steps that go a long way towards minimising both distances and time as well creating a workplace that is able to produce a product with little effort in a way based on the conveyor belt concept.

Creating offers for potential new investments (machinery and automated issuing systems)
You certainly have the best tool cabinet in the production hall in mind? This is becoming more and more intelligent and has grown to be a tool management issuing system with barcode scanners, software and integrated panel PC. Our expert will provide you with the counselling tailored to your production, as well as an offer for a new automated issuing system, including top-up and storage of the individual components.

Setting realistic intermediate targets to comply with the scheduling with appropriate task allocation
Check your project for the following factors: definition of time, personnel, expertise and target. KELCH will help you to set up on-schedule target planning or optimize your existing timeline. In so doing, we implement the information or the insights gained already in the project management.

Setting up and commissioning the tool room
Good planning and subsequent implementation both contribute to success. Firstly, the relevant specialist will work out a theoretical design and fit-out of the room. This will be followed by practical implementation in your production environment. These are the typical steps necessary to set up a tool-room, matched to your business. In short: your operational efficiency increases through simple process steps, and costs fall as a result of end-to-end hardware interfaces.

KELCH experts directly on site
The goal is to build up a schedule and hold discussions with you in your company. That way we have an overview of your production and can define specific packages of work. This produces a document listing requirements and proposed implementation. At the same time, this produces a traditional requirement specification and functional specification.

Production of your project folder
Our philosophy here is "Optimisation on demand" that helps us optimise the required production workflows, and individually adapt to your situation, your requests and your requirements. You will receive an exclusive project folder that includes all relevant modules and information from the Smart Factory Services programme.

The smart factory! We network your systems to simplify your work, with automatic data exchange guaranteeing maximum process reliability. This increases your efficiency at the same time as making you more flexible. Individually combine additional modules for a perfectly networked factory

The Benefits for you

• Optimum use of all available systems through networking
• Set-up of a central master database connected to all sub-systems (CAD/CAM, MES, ERP and others)
• Design and reconstruction of interfaces to machines and tool presetters via a tool management system
• Adaptation and redesign of internal process workflows
• Optimisation in terms of time, cost and quality
• Use of process improvement methods, such as TCT Total Cycle Time
• Continuous improvement of processes to raise process performance over time
• Cost-efficiency through standardised database and interface
• Customer care in your own company
• Individual project folder

Our services

Integration of systems (CAD / CAM, MES, ERP)
Database systems, software programs or interfaces are long established in modern production. However, the connection of various subsystems often causes enormous difficulties. The complex integration generates considerable advantages. The central database is a key factor to success. It avoids redundant data and supplies all subsystems with the right data at the right time. Thus, data changes in several places (ERP system, tool presetter, etc.) with extremely high error potential, is prevented. Your benefits: Efficient and continuous data consistency contributes to time and cost savings, leading to improved quality.

Collection, understanding, interpretation and use of data
Each program and system generates data that can be understood, interpreted and evaluated. Big data shows that information is plentiful, but is stored locally and therefore cannot be evaluated. Our experts generate a clear system landscape with you to filter out all the data that are necessary for a representative analysis.

Implementation of the individual process
We implement your unique requirements individually based on your existing and proven processes, together with the integration of new features. Thanks to the creation of a uniform interface between the mechanical and information technology sides, we offer our clients high compatibility between the individual modules in the process.

Commissioning and production start-up
GO LIVE takes place as soon as the systems are networked to each other and the interfaces are clearly defined and implemented vis-a-vis each other. We will start your smart networked production with you and offer expert advice during the initial phase. We will continue to provide you with valuable tips with regard to the modified process steps and operation modes, while you continue on the pioneering road to the perfect smart factory.

Ongoing performance updates
Where others stop, KELCH continues to think ahead. After implementation, we offer regular technology updates for software and hardware as long as these provide critical advantages for your application. We also focus on updating the tool stocks. Trust us and benefit from the state-of-the-art solutions we provide.

Optional: Continuous updating of the Smart Factory
The intelligent factory thrives on innovation. Therefore, we offer smart new features to our customers at regular intervals from the continuous development of the service concept through to the critical security issues. Our mission: Reliability at all times for each individual smart process. We achieve this due to collaboration with our high-calibre partners in the field of information technology and a renowned university. Due to this collaboration we are permanently up to date on the issues of the further development of smart factory systems Industry 4.0, and security.

KELCH experts directly on site
The cooperation between the customer and KELCH is the key goal for the smart networked factory. We undertake system integration and optimisation of process landscapes with you in your company. That way, we continuously keep an eye on your production and implement the process based on the requirements specification and functional specification. And the expert can operate on site, depending on the situation.

Production of your project folder
Our philosophy here is "Optimisation on demand" that helps us optimise the required production workflows, and individually adapt to your situation, your requests and your requirements. You will receive an exclusive project folder that includes all relevant modules and information from the Smart Factory Services programme.

The future is here! Our knowledge for your own tool database. The benefits for you: We digitalise your tools to enable you to work without stress. This increases your efficiency at the same time as making you more flexible. Individually combine additional modules for a perfectly networked factory.

The Benefits for you

• Standardised digitalisation of your complete production by a KELCH expert
• Cataloguing of the tools in the database with regard to 2D/3D graphics, complete tool assemblies, images and construction files
• 100% master data maintenance of tools, machines, tool presetters and workshop logistics
• Modern database in compliance with the latest DIN 4000 standard / ISO 13399 standard
• Use of the KELCH tool database
• Reduction of multiple data retention by end-toend data management in the central system
• Time savings by Kelch providing digitalisation work
• More effective work by minimal searching for tools
• Customer support in your own company
• Individual project folder

Our services

Database setup with tools in accordance with DIN 4000 / ISO 13399, testing and measuring equipment, storage systems and CAD/CAM programs
The core of an optimum system landscape is the central database that manages tool components, complete tools, set-up plans, measuring and testing equipment, devices, machines, NC programs and issuing systems. In our expert's view, the major cost driver is clearly a standardised data structure, consistency of tool data and tool inventory in the production process. Moreover, the multiple storage of expensive vehicles results in high costs and stocks for security considerations. After all, the tools that are utilised inefficiently cost money. All that is made transparent through a tool management system. The expert takes care of the basic data maintenance and the setup of the central database promptly. This way you do not have to take on or assign extra staff. All you need to do is transfer the responsibility and activity to an employee that will takes over data maintenance in the future.

Migration of existing and new data
Internet of Things (IoT) is the basis for industry 4.0: intelligent tools think respond and provide its own machines with data and tasks. This provides a basis for the smart communication of objects in your production. This helps standardise individual data logs with new technologies, while the bar codes or RFID chips is an important component in the exchange and collection of data. This is the only way for the scanner and computer to read the tool data and forward it online. In conclusion: your machines are networked and communicate with each other.

Designing and sorting of components in issuing systems
Customer-oriented engineering is customer support and practical work. In practice, the major part is the digitizing of various components in the virtual database. The second part will be followed by the designing and sorting of the virtual components. We will set up the new issuing system together with you. We can also take over your entire interface networking. Example: Automatic ordering routine via the ERP system.

Checking of current inventories
Is stock-taking the task you will definitely have to perform at the end of the year? Then it is vital that you work with the latest information in recording tools in the database or storage and issuing systems. KELCH will promptly produce a detailed overview of all stocks through unique classification with clearly defined procedures. This would allow you to determine which components continue to be relevant and need managing. Finally, we store and label your stock in line with a degree of process logic.

Implementing a server system
The aforementioned central database for all subsystems is a part of it. However, new questions may arise in the practical implementation. Is there a central computer which acts both as a server and as a storage medium? Or is it better if both systems work separately? Should the data be stored internally in a hardware? Or in a flexible expandable cloud solution? Which cost models will ensue? These issues will be addressed jointly with your IT department to implement the best solution.

KELCH experts directly on site
A highly targeted approach to successful digitalisation is the on-site customer support. Our specialists will reliably support you, ensure correct implementation and provide all customers with their expertise. Our promise to you: we only leave when everything is working.

Production of your project folder
Our philosophy here is "Optimisation on demand" that helps us optimise the required production workflows, and individually adapt to your situation, your requests and your requirements. You will receive an exclusive project folder that includes all relevant modules and information from the Smart Factory Services programme.