Why GKN is automating 80% of their manual processes with Workerbase
Discover why GKN Powder Metallurgy has chosen Workerbase to be a critical part of their tech stack and a key driver of digitization.
“Workerbase makes the whole shopfloor more dynamic, more agile. We are much quicker in reacting to the ups and downs every production has.”
Paul Mairl
Chief Digital Officer at GKN PM
About GKN Powder Metallurgy
GKN Powder Metallurgy is a global leader in metal powder production and in precision powder metal parts for the automotive and industrial sectors. Metal powders are mixed and transported to forming stations where high pressure forming is used to bind the powder particles. After sintering, the parts become solid and get transferred into post-processing. GKN is increasing operational flexibility and worker productivity using Workerbase.
Industry
Sinter Metal Manufacturing
Company Size
>5,000 Employees
Specialties
The world's leading manufacturer of precision powder metal products, sintered structural parts, porous products and filters, sub assemblies, soft magnetic components, and e-motor solutions.
The Challenge
In their day-to-day operations, GKN wanted to address several challenges to improve their overall operational effectiveness.
- Improvement and optimization of workforce utilization, as workers were not redirected to support others during activity peaks
- Changeovers of equipment and material after each production cycle being slow and error prone, limiting flexibility for small batch sizes
- Workers often needed to access several different databases to gather information, leading to unnecessary downtime
The Solution
Frontline workers were equipped with smartwatches for streamlined data access. Using the low-code workflow builder, GKN digitized their machine changeover process.
- 1Frontline workers equipped with smartwatches to allow for streamlined data access from anywhere and anytime.
- 2Machine changeover process digitized with workflows to streamline notifications for production cycle status.
- 3Prebuilt workflow apps applied for inventory management, material traceability, and material transport requests.
- 4GKN can now independently develop, test, and implement new digital solutions to meet their unique production needs.
The Results
Increased Throughput
Digital workflows mitigated downtimes from machine changeovers and stoppages. Skills-based task delegation optimally leveraged workers to increase productivity.
Increased Flexibility
Assignment of tasks based on machine data in real time allowed for faster reactions to changes in production and a leaner approach to material management.
Cost Savings
Due to better information access and better production cycle management, GKN was able to make their production cycles leaner and reduced WIP inventory.
Discover Why Industry Leaders Choose Workerbase
- Empower workers with industrial grade smart devices and AI
- Integrate your ERP and MES systems onto one unified platform
- Leverage and analyze data from your entire manufacturing ecosystem