Siemens PLM on YouTube Siemens PLM on Twitter Siemens PLM on LinkedIn
TELASUL improves production scheduling and gets impressive results with Preactor
May 2012
With 39 years of history, Telasul is one of main steel furniture manufacturing companies in Brazil and sells more than any other in several markets. Located in a 25.000 m² Industrial Park in Garibaldi City, State of Rio Grande do Sul, Telasul currently works in three different business segments.

The Telasul Aço business unit provides seven lines of different modular kitchens; Telasul Madeira manufactures modular kitchens and bedrooms in partnership with Unicasa; Telasul PDV works with exclusive customers on special projects with individual designs. The products are sold in domestic markets and also exported to over 40 countries.

Each one of the production process areas has its own peculiarities. In the stamping section each part has several machine alternatives with different process times.  Also setups vary according to the production sequence and special matrices that impact scheduling. The painting section has a big production line that works with multiple products on capacity limited hooks. The door assembly process has many flexible resources flexibility but the limited of labor restricts simultaneous use. Finally, the packing section requires all parts are available to assembly the products, and the scheduling sequence has a big impact on productivity.

Telasul is a company owned by the UNICASA Group which had implement Preactor before and decided to extend the project to replicate the benefits achieved previously.

Giancarlo da Silva is IT Manager at Telasul.
“After we reached all the objectives with the Unicasa Project, we verified that the solution had all the attributes to meet Telasul requirements. We went further by proposing with ACCERA an implementation to be completed in 60 days and this completed successfully”.

Replicating the concepts and assumptions that led to the success in the previous project, the company maintained its focus on seeking pragmatic solutions to problems. “Using this methodology of deployment, more practical and less theoretical, it was possible for us again to gain real results in making our company more Lean with Preactor”.

The solution includes the complete integration with Focco 3i ERP with Preactor, ensuring that all data and information is updated on the corporate system and the APS system is used like specialist tool for production planning and scheduling and no parallel database is maintained. The production updates are made in the factory by a MES (Manufacturing Execution System) supplied by the NC Systems company.  This information is used by Preactor to update the schedule progress and repair the schedule according to the current factory status. The integration was made by a tool called ACCERA CONNECT, which communicates directly with the ORACLE database to obtain the updated information in real time.

Telasul uses Preactor 400 APS, which covers are the requirements to provide materials synchronisation and the optimization rules used in this solution. Recently Telasul completed an upgrade to the Preactor v11.2, enjoying several new improvements that are periodically launched by Preactor International and can be updated through Plug & Play and without interference to normal system usage.

The deployment schedule was very challenging.  Even so, the solution was completed without any delay. The project was completed in just 50 days including specification, installation, business rules development, revisions, training and start-up monitoring.

Giancarlo again.  “The partnership with ACCERA has brought us the additional benefits of consistent learning with the deployment methodology to deliver successfully projects, which is not an easy task to perform in the industrial sector”.
Jonatas Girotto is the key Preactor user.

"Preactor is very flexible and simple to use. Through Preactor, I can manage bottlenecks, plan overtime, evaluate preventive maintenance and set up several business rules. The reports are very friendly and easy to understand by the factory. Passing data with ERP takes less than five minutes and the automated sequencing can program all the plant in less than one minute. The complete cycle of data import, plan generation, analysis of multiple scenarios and sending information to the plant takes between 30-60 minutes."