Time-to-market reduced by 20+% due to digital transformation of the technological chain in the production of “Stalkanat-Silur”
#case study#industry 4.0

The production association “Stalkanat-Silur” is one of the largest producers of steel ropes and reinforcing strands in Eastern Europe. Leader in Ukraine, producing over 60 thousand tons of products per year.

The company supplies products for the needs of the mining, oil and gas production, and metallurgical industries in more than 30 countries around the world. It has a wide range of products, high variability of technological processes (450+ standard sizes of ropes and 400+ standard sizes of steel wire), and operates in a continuous production cycle.

IT-Enterprise / Clobbi specialists have developed a phased digital transformation plan for Stalkanat-Silur, taking into account the specifics of organizing profitable production in conditions of low marginal income in the industry.

Background, concept, challenges

The management of Stalkanat-Silur was looking for ways to optimize business process management mechanisms to increase customer focus, which would help to reach a new level of customer service, namely:

  • allowed to fulfill orders in a short time;
  • helped to manufacture products according to the individual specifications of clients.

Market demands and customer expectations strictly regulate the interaction between market players and formulate the main challenges, namely:

  • the ability to maintain a low price of products with an overall low margin of the industry;
  • accurately predict the timing of supply;
  • keep customer focus at a high level.

The company has already used customized, but disparate IT solutions based on standard ERP and self-created software products and services to solve management problems. However, the aggregate of systems did not meet the growing level of demand and had problems with data synchronization. Non-integrated systems required a reinforced staff of heterogeneous specialists. Therefore, the managers of the Stalkanat-Silur company had to decide how to manage business processes in the future.

“We chose the IT-Enterprise / Clobbi system because it has already proven itself in the market and is supported by a qualified team of integrators with relevant experience for us. This is an easy-to-use solution that we can develop on our own in the future ”, – Andrey Muksimov, Chief Financial Officer of the Stalkanat-Silur Production Association.

After consulting with the IT-Enterprise / Clobbi project team, including engineers, software developers and business analysts, it was decided to start digital transformation to improve coordination of manufacturing operations. The long-term goal is to create a SmartFactory ecosystem based on Industry 4.0 technologies.

Design solutions

The Industry 4.0 concept assumes the creation of single information space for the rapid interaction of machines (equipment, production devices, personal computers) and people (managers, specialists, customers).

Within the framework of this concept, IT systems should offer optimal solutions, giving a person the opportunity to deal with more complex, creative tasks.

Road map

  • Internal Roadmap
    Within the Stalkanat-Silur company, a project team has been created, goals and objectives have been formulated, a plan and target process models have been developed, and interaction rules have been established.
  • Infrastructure
    The necessary infrastructure has been deployed to carry out the digitalization of processes.
  • A step-by-step diagram with stages of a business process
    IT-Enterprise / Clobbi experts studied the Stalkanat-Silur technological chain to optimize and improve each stage of the production cycle:
    – order processing;
    – management of stocks of basic raw materials;
    – production planning;
    – calculation of a load of work centers;
    – issuance of production tasks;
    – registration of performance and material accounting;
    – quality control;
    – warehouse management and logistics operations.
  • The business solution, Industry 4.0
    Reengineering of business processes is carried out in the Industry 4.0 concept, carried out in stages and using software business solutions that are parts of Clobbi SmartFactory.

    Clobbi Cable Designer
    – development of a regulatory and technical framework.
    Clobbi APS – Advanced Synchronous Sequence Scheduling.
    Clobbi MES – management of the execution of production plans.
    Clobbi Smart Quality – control and management of the quality of semi-finished products and finished products.
    Clobbi WMS – inventory management and warehouse operations.
    SmartTender is an electronic platform for commercial and government tenders – for local tenders for the services of transport carriers.
    Clobbi IIoT – Industrial Internet of Things – a system of interconnected computer networks and connected industrial (production) facilities with built-in sensors and software for data collection and exchange.Intermediate resultsThanks to the implementation of solutions in the Industry 4.0 paradigm, monitoring and data analytics at the enterprise are now carried out centrally and online. Stalkanat-Silur specialists make decisions based on objective information, relying on the tips of the Manufacturing Execution System (MES).A significant workload associated with the development of production sequence schedules and their redevelopment has been transferred to the responsibility of the Advanced Planning & Scheduling (APS) system.Planners now take care of more creative optimization problems by varying criteria for calculations and interacting with the artificial intelligence (AI) of a computer system.“The Clobbi SmartFactory solution allowed Stalkanat-Silur to begin the digital transformation of the enterprise and upgrade the production management system”, – Alexander Svidersky, Project Manager, IT-Enterprise / Clobbi.

Project results

The business process management system – Clobbi SmartFactory using Industry 4.0 technologies – has improved a number of indicators.

  • more than 95% of orders on time – high accuracy of forecasting and production planning.
    The Stalkanat-Silur company fulfills more orders in a short time at affordable prices for the client and in accordance with international quality standards.
  • increasing competitiveness – solutions from IT-Enterprise / Clobbi helped to optimize internal processes – load planning, logistics, resource accounting.
  • by 20 +% time-to-market, the time for the product to pass through all stages of the technological chain has decreased.
    “The regulations of business processes have become more transparent and controllable. Now we understand the status of each order and what needs each ton of semi-finished products is made for”, – Andrey Muksimov, Financial Director of the Stalkanat-Silur Production Association.
  • savings of ~ 1 million UAH per year, which is ~ 3% of the total volume of transport services.
  • 27 pieces of equipment are connected to IIoT, which gives an advantage in the online management of industrial facilities.
    In general, the acceleration of the production cycle allows the company to take more individual orders and manage the cost even in conditions of low margins.

Video case “Stalkanat-Silur”.

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