How Silca became a high performing Company 4.0
Silca was founded in 1974 in Vittorio Veneto with the name of Società Italiana Lavorazione Chiavi e Affini. Today it is an Italian company specialized in the production of keys, key duplicating machines and semi-industrial and industrial machineries dedicated to the production of keys.
Silca is part of the Key Systems Segment, the world market leader with 6 production sites, which is part of the dormakaba Group.
More than 700 million keys per year are produced in 85,000 references. More than 25,000 traditional duplicating machines and over 11,000 Automotive devices are produced in a total range of more than 150 models.
In 2010, Silca decided to start an important transformation path with the aim of changing from a production-driven to a market-driven production. This transformation required important structural, methodological and organizational changes.
The definition of a new planning model led to the introduction of an integrated planning and scheduling software. This solution must have been able to combine the needs of the market with those of our production managing a complex company like the one of Silca.
CyberPlan APS has been selected through a careful software selection as a tool that can handle the complexity of production. Sales and Operations Planning, Master Planning, Finite Capacity Planning and Scheduling define the complexity and totality of the processes involved and covered by the new solution.
To date, through a complete mapping of the entire capacitive structure with the management of both primary constraints (materials, work centers/machines) and secondary (man/tool resources), Silca is able to simulate the whole enterprise complexity in less than 2 minutes.
Any exogenous variation (suppliers and/or variation of the demand) or endogenous (productive constraints), once examined, is simulated through different scenarios and the resulting impacts, analyzed in order to allow Silca to undertake in short amount of times, the most apporopriate countermeasures.
The implementing of CyberPlan lasted 6 months and led to considerable results in the Key sector, like:
- Setup times reduction;
- Lead time and Work In Progress reduction;
- Customer’s Service at a level of excellence;
- Productivity increase.
In the software selection phase, we identified the potential of rapid repetitions in the production plan simulation to optimize all the critical factors of production (people, production plants, materials). We also kept into account the support of Key Performance Indicators that could be defined on the specific needs of our plant resulting from market demand (Decision Making Process supported by predictive analytics).