Company name: Borg Automotive Sp. z o.o.
Business profile: Automotive parts regeneration
Scope of implementation: SCADA-MES system and a series of modifications aimed at
adapting the standard version of the system to the client’s specific requirements
Supplier information: APLIXCOM Solutions, +48 (12) 376 95 99, 789 204 519,
www.aplixcom.pl, www.scada-mes.pl
Borg Automotive Sp. z o.o.
For over 40 years, we have been working to deliver the best remanufactured automotive parts to the European aftermarket, meeting OE standards.
Currently, we are developing a family of attractive brands such as DRI, Elstock and TMI. BORG Automotive is a workplace for more than 1,500 ambitious employees in Denmark, the UK, Poland, Belgium, and Spain, who collaborate to make us a renowned and reliable supplier – today and in the future.
We now remanufacture over 2 million products across all our brands. We are proud to have grown based on a business model that significantly reduces carbon dioxide emissions. This means that BORG Automotive protects the environment by using 79% less energy compared to the production of new products.
Implementation Description
The role of the Aplixcom SCADA-MES system was to monitor and assist in production accounting, oversee product quality, and provide real-time support in resolving process issues. The system was required to operate in two languages, as the implementation was carried out simultaneously in two plants: one in Poland and one in the United Kingdom. For the Polish plant, the project was initially launched on two production lines, with plans to expand to the remaining three lines.
Implemented Modules:
- Planner – A visualization of the production plan and access to real-time data supports the monitoring of production progress and improves response times to the current situation within the supervised area. Data is exchanged bidirectionally with the ERP system used by BORG.
- Main MES Module – This enables data collection from 83 workstations, real-time reporting, registration of good/bad parts with defect identification functionality, ordering parts directly from the warehouse, and requesting technical support at the workstation.
- Charts and Reports – The production plant operates in two shifts: 6 am–2 pm and 2 pm–10 pm. The charts display: operator work time, defect types, good/bad parts, workstation status, product statistics, and employee statistics. Access to the application’s database is planned to allow BORG to perform extensive analyses based on BI mechanisms.
At Borg Automotive we take responsibility—not only for our partners but also for the environment. We are proud to build our business on a model that significantly reduces CO2 emissions. With the SCADA-MES system, we’ve contributed to this model by drastically cutting down on the use of paper for printed documentation.
The system efficiently supports the management of our production processes, which are characterized by the high variety and diversity of remanufactured automotive parts. We can confirm that investing in Aplixcom SCADA-MES was definitely the right decision. We gained extensive insight into our production area, and as a result, we are confident of achieving a return on investment in specific sectors.
At Borg Automotive we take responsibility—not only for our partners but also for the environment. We are proud to build our business on a model that significantly reduces CO2 emissions. With the SCADA-MES system, we’ve contributed to this model by drastically cutting down on the use of paper for printed documentation.
The system efficiently supports the management of our production processes, which are characterized by the high variety and diversity of remanufactured automotive parts. We can confirm that investing in Aplixcom SCADA-MES was definitely the right decision. We gained extensive insight into our production area, and as a result, we are confident of achieving a return on investment in specific sectors.
Current state and implementation:
As a result of an analysis conducted at the client’s site, the need for modifications to the SCADA-MES system was identified, allowing it to become almost a „tailor-made” solution. A key feature was the implementation of technological call management and enabling parallel operations across multiple workstations within the same production area. Additionally, a two-way data exchange interface between the ERP system and SCADA-MES was developed.
The Aplixcom SCADA-MES system retrieves the work plan, along with additional information about the technological operation, including necessary product parameters, technological notes, and attached process documentation. Feedback to the ERP system includes material requirements, process issues (e.g., series halts, series reductions), and, finally, production reporting. Any changes to ongoing production orders are prohibited in the ERP system, with management of these orders being handled through messages from the SCADA-MES system.
The implementation initially covered 66 workstations in the Polish plant and 17 in the UK. Both plants have been continuously developing since then—nearly three years after launch, the UK facility now operates 60 workstations. Meanwhile, in Poland, the system has been expanded to two plants, covering a total of 260 workstations. These figures are not final, as the growth of BORG Automotive necessitates further development of the SCADA-MES system as well.
The SCADA-MES application is also continuously evolving in terms of functionality, based on user feedback. Rapid implementation of changes is possible because SCADA-MES is a proprietary solution developed by Aplixcom.
Customer Benefits
As a result of the implementation, our client gained the following advantages:
- Real-time Series Tracking – The client can now track the current status of a production series, specifically where (at which production workstation) the series is located. A significant added value is the dashboards displayed in the production area, created by Aplixcom at the client’s request. Operators and shift managers can at any time locate a production series on dedicated TVs and check the process's progress. This also allows for the analysis of feedback, such as:
- Reasons for production series downtime,
- Information on the quantity of remanufactured parts,
- Information on the production time for each series.
Additional Customer Benefits
Enhanced Reporting and Process Improvements – Since the implementation, numerous external reports based on feedback have been developed. These reports include details such as the types and quantities of defects at production workstations, allowing the quality control team to receive valuable data for process improvements. Key improvements include:
- Warehouse Management – Materials are only released from the warehouse in the exact quantities ordered through the production system, enabling better control of work-in-progress inventory.
- Up-to-Date Documentation – Access to always current and required production documents (images and PDFs) at each workstation ensures that operators have the necessary information at hand.
- Reduced Paper Usage – Paper reports have been reduced from dozens of pages per production series to just three essential pages, supporting the labeling of products distributed across the remanufacturing area. This has significantly cut down on the use of hundreds of reams of paper annually.
- Identification of Bottlenecks and Cost-Saving Operations – The Aplixcom SCADA-MES system has enabled the client to identify bottlenecks in the production process and pinpoint operations that generate additional costs. As a result, several product remanufacturing processes were optimized, leading to better productivity and lower costs. Additionally, the system improved various aspects such as the process of ordering parts from the warehouse and communication between operators, which together have contributed to achieving the expected results set prior to the SCADA-MES implementation.
- Improved Quality Control for New Products – The presence of an IT system in the production process has supported technological and quality control for newly launched products. This gives the client confidence in the quality of their products, allowing for continued growth by expanding their portfolio.
Company name: Major Sp. z o.o.Business profile: machining of components using CNC technology Scope of implementation: ERP system and SCADA-MES solution Supplier details: APLIXCOM Solutions
Company name: Borg Automotive Sp. z o.o.Business profile: Automotive parts regenerationScope of implementation: SCADA-MES system and a series of modifications aimed atadapting the standard version
