More efficiency through reorganisation
Following the integration of a second SMT line in mid-2023 and the introduction of two-shift operation at the beginning of 2024, HEITEC is continuing to adapt to the good order situation with a comprehensive reorganisation of intralogistics and production.
Adaptability is essential in a constantly changing world. HEITEC AG's Electronics division began significantly expanding and reorganising its branch in Eckental in the middle of the year. The measures are based on a far-reaching analysis of the value streams from incoming goods, quality control, the warehouse, production through to outgoing goods and sales forecasting. The aim was to increase efficiency and productivity through area clusters, more options for electronics production, system assembly and additional service facilities as well as optimised, consistent workflows and simplified, improved value streams.
Based on the analysis, HEITEC derived a concept for a new intralogistics and production structure in order to meet the challenges of the market flexibly in the future and ensure continuous growth. Warehouse and production were equalised, clearly structured, clustered and expanded. This resulted in an increase in the production area for systems, optimisation of the material flow, automation of test systems and, last but not least, greater convenience for employees. The transformation was carried out during ongoing operations so that production downtime could be almost completely avoided. The new possibilities for system assembly also benefit the processing of a large order for innovative medical technology, which is to be manufactured in Eckental for international markets.
"By using the most advanced technologies and continuously optimising processes in the mechanical and manual production areas, as well as the paths between the various production steps, we are dynamically adapting to market conditions and business growth. However, the optimisations do not end with the production facilities, but also extend to all (cross-departmental) processes involved in the smooth running of production. Last but not least, an optimised production process and embedded, controlled lifecycle management improve our flexibility, customer focus and therefore also our competitiveness," says Stefan Pechtel, Head of Operations and Deputy Business Unit Manager at HEITEC Elektronik.
Extended options for system production
As a result of the recent favourable order development, the expansion of system assembly had top priority. To implement the concept, approx. 2000 m² of rented warehouse space was returned to in-house use, almost doubling the production area for systems. Assembly activities were also transferred from the electronics production area to the system production area, so that this area was also reorganised and equipped with additional workstations for the future. The processing of (large-scale) projects is now centred in one area which, with an optional expansion area, offers all the flexibility needed to adapt to a wide range of requirements and customer requests.
In the warehouse, the routes between incoming goods, incoming goods inspection and subsequent storage have been combined and optimised on one level. The transport routes and the options for stocking components and material flow have been reorganised and expanded.
Improved workflow, additional service areas and optimised working conditions
HEITEC also equalised and restructured the test area in electronics production. A flying probe tester was automated with a PCB loading/unloading system to such an extent that manual handling is almost completely eliminated. Automatic optical inspection (AOI), boundary scan, X-ray, functional, high-voltage and limit load tests and climate tests are also available as in-house test and inspection procedures.
The optimisation of working conditions was also an important aspect: concentrated work processes and short distances through area clusters, new lounges and social areas should further increase comfort for employees in the future and create an even closer exchange between the teams.
HEITEC carried out all the necessary conversions, such as the application of 1,000 m² of ESD flooring, as planned so that the operational business was not affected. The steps are designed to enable further customisation and automation of existing systems and to be implemented quickly as required. The branch is therefore well equipped for future tasks.
