Plastics moulding and welding
The Freilassing-based company, founded in 1945 and a member of the Renolit Group, is known for its high-quality customised plants for the automotive, medical, office supply and packaging industries. Customers benefit from its many years of experience in plastics welding and moulding. The automotive industry is its largest customer, accounting for more than 50 percent of orders. In this sector, Kiefel manufactures a wide range of equipment and tools used in the production of door and side panels, as well as airbag and glove compartment covers, amongst other things. There is a particular demand for flexible machine concepts in the packaging industry, since the materials being handled change as rapidly as the finished products themselves. In order to rationalise its order planning and handling processes in the face of increased productivity and almost 100 % capacity utilisation, Kiefel was obliged to invest in a software package which would control the entire production sequence.

Helmut Kuttler opted for the tried-and-tested business management software from SAP, scheduled to start handling production with effect from 3 July 2000. "We introduced all the SAP modules at Kiefel," explains Kuttler, "from procurement through to controlling and financial accounting. Of course, incorporation of the electrical design data was a key component, since the bills of materials for our machines form the basis for orders". The SAP software administers all business management processes within the company. With a wide range of standard applications, it offers an infrastructure for handling the bulk of business information processing. Data is entered and updated in real time, and is then made available to the various different departments. The software is precisely tailored to the user's specific requirements. However, optimum results can only be achieved in conjunction with the various CAD and CAE programs used throughout the company.

Interface links design to materials management
In late 1999, Kuttler commissioned its CAD design engineer Kurt Tammer to analyse the interfacing opportunities of the CAE programs then in use for electrical design work, namely EPLAN 5 and Elocad. When rationalisation prompted the merger of the two arms of Kiefel GmbH in 1994, all electrical design engineers used EPLAN 5 for project management, whilst continuing to use Elocad for handling older orders, spare parts deliveries and documentation. All new circuit diagrams, control boards and enclosures were designed and project-managed with EPLAN 5. At the time, EPLAN 5 was already established as the standard for the automotive industry, and hence it was only logical for this program to find its way into Kiefel as well. 
Kurt Tammer gathered information and held a number of meetings in order to assess the 
expansion opportunities afforded by both EPLAN 5 and Elocad. Because there was no way of linking Elocad to SAP, he decided that all future plans should concentrate on EPLAN 5, which was to be prioritised as the favoured CAE system. EPLAN Software & Service were able to provide the required interface to link to SAP. Above all, this add-on tool may be adapted to suit individual requirements and can then be used with every EPLAN 5 installation. "Because we were already working with EPLAN, it was clear we needed to incorporate our electrical bills of materials into SAP, because typing them in manually would be so time-consuming", explains Tammer. "Without integration, it would first have been necessary to search for the material or semi-finished product in the materials management section of SAP, and then enter it manually in the circuit diagram and bills of materials. Under such a system, the bill of materials function in EPLAN 5 cannot be used to optimum effect. We would have needed an extra typist just to type in all the bills of materials – a complete waste of time and money".

Interface adapted in line with requirements
After initial consultation with the sales department of EPLAN Software & Service, Tammer compiled a "wish list" so that his ideas and requirements could be incorporated into the purchase order. Wherever possible, these were then included in the specifications. Tammer's staff, a team of 25 electrical design engineers, needed preparation before they were able to work with the interface, the SAP software and EPLAN 5. The training for the design program was provided by dedicated experts at EPLAN Software & Service. However, the specially configured interface posed a problem. Kurt Tammer himself seized the initiative, drew up his own training documents, and held a two-day course to train his staff in use of the interface. This gives everyone the opportunity to check the documents in the event of possible inconsistencies.

Adaptation of the program can only be achieved in situation
The interface was already available as a basic program, but the individual requirements outlined in the specifications were put into practice on site at Kiefel. As SAP is always very highly customised, it makes sense to implement the settings on site. Moreover, direct dialogue with the customer is crucial, so that problems can be identified and rectified more quickly. By the start of production on 3 July, the interface with EPLAN 5 and SAP needed to be fully functional. Tammer confirmed: "During the introductory period, continuous support from EPLAN Software & Service was vital. At this stage, not everything was working the way I wanted it to, and various problems needed to be resolved. We kept on testing everything until it worked". With such superb planning, all new orders were up and running via the programming interface in time for the envisaged deadline. There were no production hold-ups or failures whatsoever.

Any minor defects are soon rectified 
One particular feature of SAP adaptation, which was not always easy, was the excellent cooperation between the two parties. Today, everything is working well, but various factors have prompted a number of amendments. There are also still some points outstanding form the original specifications which have yet to be implemented. "Unexpected errors still cropped up from time to time, but these were soon rectified", explains Tammer. "However, they were never so serious as to impair production". Kurt Tammer was particularly pleased with the new functions of EPLAN 5.30. "The system is now much better, and works superbly. Above all, the material data from the bills of materials can be incorporated automatically. This puts an end to unnecessary typing". 
Engineer Helmut Kuttler is equally delighted with the way the SAP link has worked: "We had comparatively few problems. Particularly in the area of the CAE link, everything was a great success. Some 220 users have already been incorporated into the SAP system". 

Because cooperation between Kiefel and EPLAN proved so successful, the company has now placed a new order for a program extension. Tammer was forced to change the material status, because under the old system, the company was experiencing problems with materials procurement. It was unable to authorise bills of materials from old orders for spare parts deliveries because the original materials are no longer available. "We have now created a new status which authorises the bills of materials once a replacement material has been found". Within a short space of time, EPLAN Consultant Andreas Laquai had programmed this vital new part of the program.

Last edited: 2002-07-16 14:47