Case Study Psipenta/ERP: The Heartbeat of Manufacturing at Simtec Systems
With PSI's ERP system, the manufacturer of motion simulators has both individual and series production under control.
Simtec is a manufacturer of sophisticated motion simulators for the automotive and entertainment industries, as well as digital signage systems. A period of rapid growth led to numerous changes in the company's processes and ultimately necessitated the introduction of an ERP system. As a central data hub, PSIpenta/ERP is now the heartbeat of the factory.
About Simtec Systems GmbH
Simtec Systems GmbH (Simtec) is a manufacturer of real-time motion simulators. Its core business includes test systems for the automotive industry and “flying theaters” for the entertainment industry. Simtec is even the world market leader in the field of tank test systems. The systems work with real fuel and are used by well-known OEMs such as Volkswagen, Audi, and the Peugeot Group. However, its customer base also includes automotive suppliers, who use special simulators to test individual components, such as car seats.
Challenges
Whether entertainment, flight or driving simulators, all simulation systems are complex products that are developed over periods of one to two years and to a high degree by hand. In the past, Simtec worked on individual customer systems one after the other. Today, however, several orders have to be processed in parallel, and increasingly in small series. This means that systems that have already been developed are manufactured again, if necessary with minor customizations. Simultaneously processing several orders requires complex planning and certain process standards.
Production characteristics
- Contract manufacturing of one-offs and small series
- High proportion of design
- Complex planning processes
- High proportion of manual work (manufacturing)
- Project durations of up to two years
Objectives of Simtec
When it became clear that the growing number of orders would require fundamental changes, Simtec began looking for a software that could handle the growing amount of data. The aim was to gradually replace the various solutions used in the individual departments – starting with special programs for the electrical department and including numerous individually compiled Excel spreadsheets. Specifically, the ERP system was to ensure a high level of data integrity, improve inventory management and calculation, control resources, and ensure the traceability of parts as well as the feasibility of agile development projects.
The main objectives
- Development of a central data hub
- Establishment of a high level of data integrity
- Improvement of various processes, e.g. inventory management and calculation
- Traceability of parts
- Feasibility of agile development projects
Approach
PSIpenta/ERP was established as a company-wide database and isolated solutions were gradually replaced. The system maps all the processes involved in both make-to-order production and the growing proportion of small-batch production – in each case on the basis of customer orders.
Realization
Support for project business plays a particularly important role and extends from the development phase, through procurement and cost accounting, to project controlling and after-sales.
The integration of the PDM system, from which PSIpenta/ERP receives the article and parts lists, is of a similarly high priority. These lists serve as the basis for creating the project-related production orders. Here, Simtec has used PSI Click Design to create a special dialog that includes all transferred data fields for an article. This allows employees to see the most important design properties of the article at a glance.
Result
The three most important improvements since the introduction of PSIpenta/ERP:
- Established integrated processes
- Created a high level of data and process transparency
- Accelerated business processes
The company benefits, for example, from being able to see the current procurement status of all the components required for an assembly at any time and at a glance. The successful introduction of the software solution is attributed by the company to the good cooperation with the PSI consultants on the one hand, and to the great commitment of all Simtec employees on the other.
Conclusion
Precise planning is especially important in complex projects. With PSIpenta/ERP, Simtec has found the right solution and is well prepared for future challenges in the world of sophisticated motion simulation.
