The Dieffenbacher Group manufactures presses and complete plants for producing wood-based panels, forming metal and composites, and recycling waste wood. The strongest sector in terms of sales of the family-run company, which was founded in 1873 and today employs over 1,600 people worldwide, is providing plants for the production of wood-based panels. Dieffenbacher is the global leader in this sector together with a German competitor. The three business divisions, Wood-Based Panels, Forming and Recycling, generate annual revenues of 400 to 450 million euros. The company's customers include not only global manufacturers of wood-based panels and large furniture manufacturers but also, for example, carmakers.
Product development and manufacturing have a decentralized organizational structure. Core products such as presses for wood-based panel production and forming presses are developed and manufactured at the headquarters in Eppingen. The subsidiary in Bielefeld is responsible for developing machines for shredding logs; the site in Leverkusen develops, among other things, huge drums for drying wood chips, and the Finnish subsidiary develops finishing components such as grinding lines and stacking systems. Production takes place in Germany, the Czech Republic, China and Canada, and at external suppliers.
The wood processing plants are customized to a great extent, depending on how wide and thick the wood panels are to be, what materials the customer wants to process, and how many cubic meters they want to produce per day. To reduce the engineering effort involved, the company has developed a modular system that allows certain components to be configured on an order-by-order basis. The complete absence of engineering is, however, very rare. Efficient engineering design is important when it comes to shortening project lead times, which can be 12 to 14 months from the time an order is received to the production of the first panel.
Numerous components and systems from suppliers are incorporated in the production systems. As general contractor, Dieffenbacher assumes responsibility for planning the entire plant, which in the case of wood-based panel plants, for example, can measure the size of several football fields, as Matthias Rebel, Head of Technical Information Systems, explains. In addition, the service department is responsible for modernizing existing plants and offers customers innovative services such as the IoT platform EVORIS, which they can use to monitor the quality of their production and perform predictive maintenance. This service is sometimes a crucial factor in the context of awarding of contracts.
Requirements relating to the PLM system
"The products services that we offer are very important to us. They require that we represent the as-maintained state – whether this will be done in the PLM system or the ERP system has not yet been decided," says Rebel. Plants have long lifecycles of 20 years or more and are subject to change throughout their lifetimes. Thomas Schmetzer, CAD/PLM administrator and head of the PLM project, adds that mapping the electrical and electronic components in the product structure also poses a major challenge. "We have to document the complete product structure – not only that of our own machines but also those of bought-in system components – in a way that ensures that it can be traced over the entire lifecycle.”
One of the results of the consulting project with PROSTEP is that Dieffenbacher should no longer design its plants within a predominantly assembly-oriented framework, but rather in a function-oriented manner. As Schmetzer explains, "An assembly-oriented approach to work has a considerable downside, especially in the context of a modular concept, as it increases the complexity and variance of our modular system. If you were to differentiate by function instead, variance would be much smaller and the modular system more manageable."
However, a prerequisite for function-oriented design is that the PLM system not only makes it possible to map functional structures but also to transfer them to assembly or service BOMs. Making changes to structures in two systems and ensuring that they remain synchronized is much more difficult.
It also requires a rethinking of the organization, as someone has to remodel the structures in the PLM system. This would normally be the task performed the people in work preparation who are more at home in the ERP system.