The company DF Electric, after more than 40 years specializing in the design and manufacture of electrical protection material, has taken a decisive step in its industrial transformation strategy with the implementation of the Ibernova MES system, a solution that has allowed it to move towards a more digitalized, connected, efficient and future-ready factory thanks to the capabilities of the MES system.
With a consolidated history of the values of quality, reliability and innovation, DF Electric had set itself the goal of evolving towards a “factory of the future” that combined digitalization, operational intelligence and a human vision of industrial processes. In this context, the collaboration with Ibernova, a leading industrial software manufacturer in Iberia, has made it possible to deploy an ambitious transformation plan supported by the MES system, which has represented a before and after in the way of managing productive activity.
“The project allows us to optimize processes, increase efficiency, improve traceability and strengthen our commitment to innovation and sustainability,” explains Jordi Bartoli, deputy general director of DF Electric. According to him, the integration developed together with Ibernova between SAP and the MES system has opened the door to management based on real-time data, taking advantage of the full potential of the MES system to facilitate obtaining KPIs and making more agile and informed decisions.
Adapt to the increasingly demanding production environment
Before the implementation of the MES system, DF Electric faced significant difficulties in obtaining plant indicators and sequencing operations, processes that in many cases depended on Excel sheets and less agile management for an increasingly demanding production environment. Complexity was especially relevant in products with multiple manufacturing phases, where ordering tasks, forecasting loads and estimating deadlines was more expensive without the support of an MES system.
With Ibernova’s MES system, orders entered into SAP generate manufacturing orders that are instantly transferred to the system, from where the company manages the entire production operation from start to finish through the MES system. This integration has made it possible to unify process criteria, improve sequencing using the MES system’s own calendar and Gantt chart, and have a more precise reading of delivery times to reinforce compliance with clients and internal coordination.
According to the company, the operator can now report data more quickly thanks to the MES system and access with a single click, from the touch screen, the necessary documentation for each product, such as guidelines, plans or labels integrated into the MES system.
Measurable results in efficiency and operations
The impact of the project is already reflected in specific indicators. DF Electric has reduced the use of paper by 75% compared to the beginning of the project, largely thanks to the implementation of the MES system; has simplified operations in certain products, going from two or three phases to a single one, and has managed to reduce the times granted in some processes by between 20% and 65%, with the consequent positive effect on costs that the MES system facilitates.
In addition, the company now has a faster and more accessible view of key indicators thanks to the MES system, such as plant productivity or the presence of staff on time, which facilitates operational monitoring and the monthly analysis that is presented to General Management. The improvement has also reached the operator’s workplace, who can report data more quickly through the MES system and access the necessary documentation with a single click.
Greater visibility and better coordination
The implementation of the MES system has also had a direct effect on internal logistics. When an order is notified as completed in the MES system, the system activates the flow to the warehouse and immediately informs the finished product area to proceed with its collection, avoiding unnecessary accumulations of material and improving coordination between areas thanks to the MES system.
The company now has a faster and more accessible view of key indicators thanks to the MES system
For Francesc Arjona, industrial director of DF Electric, “one of the great values of the project has been to convert operational information, managed through the MES system, into a useful tool to continuously improve processes.” The company also highlights that the deployment of the MES system was agile, had effective dialogue throughout the process and met the initial expectations linked to the reduction of paper, obtaining indicators and the simplification of production phases.
DF Electric considers that the transformation carried out, supported by the MES system, lays a solid foundation to continue advancing on its roadmap towards Industry 4.0. Among the next steps, the company plans to consolidate its internal processes, continue promoting continuous improvement and adopt new technologies that complement the MES system and allow it to strengthen its competitiveness.
The case of DF Electric shows how an industrial company with a strong technical specialization can accelerate its modernization by relying on an MES system connected to its management ecosystem. In an environment where plant visibility, traceability and the ability to make decisions quickly make the difference, the collaboration with Ibernova demonstrates the value of an MES system as the axis of digitalization focused on concrete and sustainable results.
