Engelmann Sensor GmbH in Wiesloch-Baiertal overhauled its production workflow by deploying manufactuss electronic Kanban system IKS, transitioning from a push approach. The newly implemented pull mechanism closely aligns subassembly and final stages, ensuring synchronized operations. Integration near the ERP accelerates material handling, minimizes booking errors, and increases delivery consistency. Engelmann autonomously manages its production, warehouse transfers, and supplier processes, achieving efficiency improvements, strengthening planning accuracy, and enhancing its competitive stance.
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Engelmann Sensor Overhauls Production to Enhance Efficiency, Delivery Reliability
Engelmann Stammsitz Wiesloch (Foto: manufactus GmbH)
Engelmann Sensor GmbH, a leading European manufacturer of heat meters, water meters and systems, initiated modernization of its production control to boost efficiency and delivery reliability. Until then, it had followed a traditional push model, centralizing subassembly planning and causing bottlenecks that delayed final assembly. By adopting a pull-based framework, Engelmann streamlined workflow synchronization between stages, reduced cycle durations, eliminated excess inventory, and improved responsiveness to dynamic market demands.
Pull system adoption eliminates assembly synchronization bottlenecks across production
Due to insufficient synchronization between subassembly and final assembly, production frequently suffered bottlenecks and delays. External consultants analyzed these challenges and recommended transitioning to a continuous pull-based methodology. Under the leadership of Production Director Klaus Zeller, the company selected manufactus’ IKS Kanban solution. The system enables real-time communication of material demands directly across each manufacturing stage, ensuring timely replenishment and streamlined workflows while minimizing inventory overstock and reducing lead times.
IKS System Live: Kanban Circuits Functional Within Few Weeks
10 Millionster Zähler (Foto: Engelmann Sensor GmbH)
Within weeks of deploying the IKS solution, Engelmann Sensor saw the initial Kanban replenishment loops activated on the shop floor, fully operational within daily workflows. In the subsequent months, the rollout expanded step by step, incorporating additional product lines and assembly components. Following this phase, the company extended IKS utilization beyond production to include coordination of stock transfers, enabling automated material flow control between the central warehouse and manufacturing areas.
Direct IKS-ERP integration ensures real-time bookings but risks misbookings
The direct integration of the E-Kanban system with the ERP platform ensures instantaneous triggers for material movements and inventory postings, enabling precise control over production workflows. However, this setup introduces risks: a single accidental full Kanban closure can create inaccurate stock records and disrupt operations. To mitigate these issues, a clearly defined protocol was implemented, temporarily suspending ERP communication during testing and modification cycles. This approach safeguards data integrity while maintaining real-time responsiveness.
Engelmann leverages three IKS Kanban for production, logistics synchronization
Engelmann uses the IKS solution in three configurations: production kanban controls assembly orders, internal transfer kanban manages material flow into manufacturing, supplier kanban integrates external vendors. Introducing supplier kanban required convincing multiple partners to adopt standardized processes. This challenge was addressed through regular training, documentation, and support from the implementation team. As a result, supplier collaboration improved, material availability became more reliable, and the company achieved smoother supply chain coordination.
E-Kanban IKS Empowers Autonomous Production Control with ERP Integration
IKS E-Kanban Board – IKS E-Kanban Tafel – elektronische Kanban Tafel (Foto: manufactus GmbH)
By implementing the IKS electronic Kanban system, production control has become autonomous, enabling coordination across assembly stages. Direct ERP integration drives substantial time savings by automating postings and minimizing manual data entry. Internal logistics benefit from error-free material tracking, ensuring consistent component availability and eliminating bottlenecks. This connectivity fosters responsive replenishment signals tied to actual consumption patterns. Overall, these enhancements yield sustainable efficiency gains that decisively boost Engelmann’s market competitiveness.
manufactus E-Kanban implementation boosts time accuracy planning delivery reliability
Engelmann Sensor GmbHs implementation of the manufactus E-Kanban-System IKS offers measurement experts a concrete example of agile production control. Accelerated commissioning, integrated ERP connectivity, and automated logistics trimmed cycle times and eradicated inventory discrepancies. The system improved demand forecasting, standardized material flows, and ensured reliable supply continuity. Enhanced delivery accuracy heightened customer satisfaction. Since deployment, Engelmann has realized operational efficiencies and elevated its market standing through improved planning security and competitiveness.
