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How to minimise your stock levels with GARANT Tool24
"Everyone takes what they need"
Company Eirenschmalz has achieved considerable savings with automatic issuing systems for C-items and rental devices. The consumption of personal protective equipment has reduced by 20 %, and tool stocks at the machine have halved. Stock levels for many items have been reduced by up to 25 % and the ordering process has been streamlined.
The Schwabsoien-based company Eirenschmalz Maschinenbaumechanik und Metallbau GmbH specialises in the production of precision parts and sheet metal, pipe, steel, stainless steel and aluminium components. When it comes to laser-based machining, it has mastered all technologies from flat bed and pipe lasering, laser marking, robot welding, edging work, laser engraving, 3D laser cutting and welding right through to powder coating. The company has around 400 employees and achieved a turnover of around 53 million euros in 2019.
Process optimisation required
In order to establish its position on the market, Eirenschmalz is continuously improving its processes. The company has been working together with the Hoffmann Group since the company was founded in 1990 whenever it comes to tools, consumables and personal protective equipment. „The Hoffmann Group is our preferred supplier“, says Thomas Plonner, Deputy Production Manager at Eirenschmalz. „We not only appreciate the high product quality but also the personal support from our customer adviser Daniel Czerny and from specialist technical advisers such as Stefan Magerstädt.
„Mr Czerny regularly keeps us up to date with regard to new products and has also introduced us to the PPE and tool issuing system GARANT Tool24. In May 2019, we got to see how this system worked at another customer‘s site, and it quickly became clear to us that we needed something like this“. However, before we went ahead with the purchase, the GARANT Tool24 had to undergo a rigorous evaluation process. In December 2019 the day finally arrived.
Perfect for every requirement
„What was important to us was that we didn‘t have to limit ourselves to a specific manufacturer“, explains Plonner. „The Hoffmann Group is therefore the ideal partner for us. Firstly, because they have many different brands in their product range, and secondly, because we can connect multiple suppliers to their system.“
In addition, Eirenschmalz was impressed by the modular functionality of the GARANT Tool24. There is a suitable compartment for every item. For example, the locker system GARANT Tool24 Locker has enough room to store a cordless screwdriver, and the individual issuing system GARANT Tool24 PickOne has several small compartments that are ideal for storing gloves or hearing protection. On the other hand, the classic GARANT Tool24 Smartline has drawers of different sizes. Other selection criteria included a materials management interface and, of course, the ease of operation for administrators and employees.
Shorter distances, charged batteries
Before the introduction of the GARANT Tool24, the employees obtained the required items from a central issuing point and from an openly accessible buffer store. „Our employees were bound to the opening times of this facility and a had long distance to walk, as there was only one issuing point for factories 1 and 3. As a result, many employees accumulated a small provision of items for themselves“, explains Plonner. „Managing the buffer store was also difficult. We had no clear overview of the withdrawals there, and always had to keep larger stocks to be on the safe side.“
To reduce time spent for fetching tools and equipment, Eirenschmalz decided to install GARANT Tool24 in both factories. Plonner continues: „At factories 1 and 3, we have installed a GARANT Tool24 PickOne individual issuing cabinet and several GARANT Tool24 Smartline drawer cabinets. In factory 1 there is also a GARANT Tool24 Locker for the removal and return of electric tools. The locker has a socket strip between the compartment rows, so we can plug in the chargers to charge the batteries directly in the cabinet compartments. The rental devices are then always ready for use.“
Self-service for all
The implementation of the two complete systems took only one month. „After a few initial start-up problems, it went quicker than expected“, recalls Plonner. „For example, we imported an Excel list with items (and their item numbers) ordered in the previous year. However, some of these items are only needed very infrequently, so we had to delete them again manually. My advice to anyone in the same position would be to go through and edit the data thoroughly before importing anything.“
In Schwabsoien, all of the production employees now have access to the two systems. At the moment, 60 withdrawals are made everyday on average, but this number is continuously increasing. Practically everything that can be managed and issued automatically can be obtained from the issuing cabinets, including consumable materials for laser cutting systems, accessories for welding operations, personal protective equipment, machining tools, office accessories, rental items, extension cables and ratchet boxes. „Now everyone can just take what they need“, says Plonner. „It works splendidly. The employees log into the system via an RFID chip, so we have a precise overview of the withdrawals and stock levels.“
Better supply, less consumption
Thanks to the cabinets‘ 24-hour operation, Eirenschmalz can now reliably ensure the secure supply of C-items and rental devices across all three shifts. As a result, employees are no longer stockpiling, PPE consumption has reduced by 20 %, at the machine, tool stocks have halved – in particular because worn tools are being used up – and the stock of many items has reduced by up to 25 %.
Quicker ordering processes
„Thanks to the Garant Tool24, we have also been able to reduce the order process duration by around 45 %. We are currently introducing a new materials management system. Our next step will be to connect it to the GARANT Tool24 and fully automate our ordering processes. Once the reorder points have been reached, the orders will go directly to the corresponding suppliers, which will greatly reduce the ordering process duration. We are also thinking of introducing Kardex Remstar lift systems or carousel racks in the buffer store. These could also be connected to and managed using the GARANT Tool24. That's something for the future.“
Stefan Magerstädt from the Hoffmann Group says: „I always advise my customers to wait until the process is running smoothly and the parts lists remain relatively unchanged before going into automated ordering processes, as then it is very quick to connect the materials management system with the suppliers.“
„We are very satisfied with our GARANT Tool24“, summarises Plonner. „At the moment, we are rolling out the system at our subsidiary company BlechTech in Augsburg, which will take us a further step towards digitalisation and automation there. For us, the GARANT Tool24 is a system that will fulfil our future needs as we venture into the era of Industry 4.0.“