Borne chooses ORBIS DSP: Interoperability and Production Optimization with Digital Twin
The product range includes doors for the home, whether classic, smooth or special design, in various heights, widths and colours, as well as functional doors. These include sliding doors, double-leaf doors, windbreak elements, as well as soundproof, thermal insulation and fire doors.
The doors and frames are manufactured on state-of-the-art production lines at the main plant in Trierweiler, Rhineland-Palatinate, which has a production area of 93,000 square meters. The finished products are stored in high-bay warehouses, where they are picked and prepared for shipment to DIY customers throughout Germany, Europe and overseas.
To manage its complex production and logistics processes efficiently and transparently, Borne relies on the ORBIS Manufacturing Execution System (ORBIS MES), which integrates seamlessly with the existing SAP ECC 6.0 system, and on SAP Extended Warehouse Management (SAP EWM) for logistics. ORBIS MES and SAP EWM are deployed in a distributed IT infrastructure.
Real-time interoperability with ORBIS DSP
With the introduction of the EDGE component of the locally installed ORBIS Distributed Shopfloor Processing (ORBIS DSP) solution, Borne has taken a decisive step forward. With the help of ORBIS DSP, the door manufacturer wants to establish real-time interoperability between the shop floor processes and the production and logistics processes, thus implementing adaptive and networked production processes.
The company has already made some progress in this direction. The EDGE component, whose scalability is a major advantage, is closely linked to the industrial automation level and takes over tasks that cannot be performed at this level. The basis for this is a digital twin of process-relevant assets, such as produced stacks of frames. Using this digital twin, which is a digital image of the real products, the actual data recorded during the multi-stage manufacturing process is transferred directly and in real time to the systems for further processing. With this transparency across manufacturing, intralogistics and planning processes, production can meet throughput time and quality expectations in a flexible but highly automated manner.
ORBIS DSP is also integrated with SAP Production Planning (based on product configuration data) for order block processing, such as cutting related order items from a common input material, and with SAP EWM processes (material call-off, inbound and outbound transportation). The next steps for ORBIS DSP are already planned. In the future, Borne also wants to use the solution in the next production step, postforming, and in finishing.
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