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How weasl became a game changer for process reliability & productivity at Staudinger

weasl in action at Staudinger

The customer

Staudinger GmbH Automation Technology

Industry: Automation technology

Company headquarters: Loiching

Employees: approx. 200

Founded: 1950

Staudinger GmbH in Loiching has been a partner for customized automation solutions for industry and SMEs since 1950. With over 200 employees, Staudinger provides the complete service package for the development and implementation of optimum automation solutions and develops and manufactures systems, devices and technical solutions for various areas of application. Staudinger stands for the highest quality, many years of experience and reliable production - all at the Loiching site on over 7,450 m². As the largest local employer, the company is also heavily involved in youth development and technical education.

Staudinger company headquarters

Initial situation & challenge

Staudinger is a renowned supplier of automation solutions for machine and plant construction as well as for the automotive industry. In a separate plant at the Marklkofen-Warth site, however, the company is dedicated to a different product: automated guided vehicles. A team of 15 employees is entrusted with the complete assembly of these robots in a cycle-based assembly line - including commissioning, end-of-line quality inspection, packaging and shipping.

Challenge #1: digital assembly instructions

Staudinger sees this plant as a factory of the future - a smart factory. From the outset, it was not an option to instruct the workers using PDFs or even printed paper. A software solution was to take over this job.

Challenge #2: Serial number management

Staudinger produces around 250 driverless transport vehicles per year on this production line. Each vehicle contains around 20 parts requiring serial numbers, which have to be scanned and traceably documented during production. The ERP was not an option for this because it lacked the necessary functionalities.

Goals

Staudinger was looking for a digital solution to optimally support the line assembly of driverless transport vehicles. The most important goals were:

Digital assembly instructions

Provide digital assembly and operating instructions that can handle multimedia content and support, document and, in the event of problems, block the work of the workers

Record serial numbers with weasl

Scan the serial numbers of the installed parts into the system and document them in a verifiable manner

Changes and adjustments in real time

To enter and provide changes and adjustments in real time where possible

Minimize sources of error

Recognize and eliminate sources of error as quickly as possible

weasl as a solution

Staudinger first came into contact with weasl at a trade fair. As a possible solution to the production challenges, it found its way to production manager Christian Sperka, who quickly recognized the added value of weasl. The initial impression was reinforced during the test phase and the weasl-guided assembly of the first prototype robots.
After a successful test run, Staudinger opted for weasl as an on-premises version and, with the support of our weasl team, introduced the system quickly and without any major hurdles in line assembly. weasl runs on a separate monitor at each workstation, but is also available and in use on tablets.

"It was relatively easy and quick to explain to the employees. Because the system is self-explanatory, there are no major hurdles to show how something needs to be done."

Christian Sperka

Staudinger Christian Sperka

Benefits & added value

Reliable guidance for employees

Once the assembly and operating instructions had been transferred to weasl, the employees had an intuitive, self-explanatory system at their disposal that guided them safely through their processes. Training was quick and without any major hurdles, so that the connected worker platform could be quickly integrated into the daily tool set.

 

Control & monitoring in real time

weasl records data, information, progress, etc. in real time and makes it immediately available. For Staudinger and production manager Christian Sperka, weasl has thus become a production control center in which all information from the assembly processes converge. weasl thus enables direct control and monitoring of ongoing production.

Ensuring quality & mastering audits

With its relatively new location in Warth, the newly established production line and products that require a high level of verification, Staudinger had to face numerous questions relating to quality assurance and auditing: How are quality gates ensured? What is the procedure for dealing with errors? What is the procedure for change loops? How can the requirements for ISO 9001 audits be guaranteed? The answer to almost all of these questions: weasl. Staudinger uses weasl for worker self-monitoring, quality steps in the assembly processes, continuous documentation, etc. This ensures compliance with all relevant regulations and standards.

 

Using the feedback function to rectify errors

Staudinger employees actively use weasl's feedback functions to point out defects, problems and the need for adjustments. Their comments do not end up on a piece of paper or on the foreman's desk. They always reach exactly the employee who can ensure that they are rectified quickly. Employees thus contribute directly to process improvement, while errors and problems are quickly rectified.

"With weasl, we keep our sources of error and problems relatively low and this is definitely a game changer for process reliability, quality and productivity."

Christian Sperka

Staudinger Christian Sperka

Outlook & potential

weasl has become an integral part of line assembly at the Marklkofen-Warth site and pays off every day in terms of employee management, quality assurance and process optimization. So far, the connected worker platform has been running independently.

In a second expansion stage, weasl is to be integrated into the system landscape and exchange data directly with ERP and other systems. In this way, Staudinger wants to make itself even more future-proof and further streamline and optimize processes.

The company is also currently examining the use of the system at its main site in Loiching. One of the mainstays of this site is the production of switch and control cabinets. Here, too, it is important to instruct fitters in a reliable process, to document data and measured values in a traceable manner and to create optimum conditions for quality checks and audits - all of which are key disciplines for weasl.

weasl in action at Staudinger

"weasl is our control system in the assembly line and we can integrate our CIP process perfectly into 'doing'."

Christian Sperka

Staudinger Christian Sperka

Get to know weasl yourself

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