Elkamet improves production processes with data

Elkamet GmbH has been developing and producing high-quality plastic components for the automotive and lighting industries since 1955. The family-owned company, headquartered in Biedenkopf, Hesse, currently employs more than 1,200 people across six locations. The production processes are based on state-of-the-art technologies, generating large amounts of data—valuable raw material that, for a long time, provided little business benefit. “We had collected our extensive production data in an Abas ERP system,” explains Julia Günther, Developer at Elkamet. “However, we lacked the tools to process, analyze, and provide this data in a centralized reporting system.”
As a result, managers had little fact-based insight to optimize production processes. Production staff could not quickly get an overview of their current situation, and advanced analyses of production data were out of the question. “At that time, we already knew a modern business intelligence system would help,” says Julia Günther. “The full range of possibilities only became clear through our partnership with ORAYLIS.”

Modern Cloud Platform Creates Future Security

Matthias Petig, Senior Consultant bei ORAYLIS.

Together with ORAYLIS, Elkamet built a complete Modern Data Warehouse (MDWH) in the Azure Cloud in a short period. “We migrated all relevant data from the ERP system using Azure Synapse Analytics and made it available for the desired use cases. The data is updated several times a day,” explains Matthias Petig, Technical Project Manager at ORAYLIS. “Reporting and self-service analyses are then carried out via Power BI.” Reports are embedded directly into the employees’ work interfaces. “Users don’t need to log in or navigate extensively to access the data. Most importantly, there are no licensing costs for the many machine workstations. The embedded solution covers everything, including updates and maintenance.”

Another advantage of the cloud approach is that storage and computing resources can be scaled independently to any desired level. Elkamet can also easily integrate new applications in the future, such as AI use cases. “This is simple because all Azure services work seamlessly together. Technologically, Elkamet is very well positioned for the future,” adds Matthias Petig.

Rapid Development Through Agile Methods

Agile methods also contributed significantly to the fast development pace. “Through the ORAYLIS team, we learned and appreciated agile working methods,” says Julia Günther. “We worked in two-week sprint cycles. After each sprint, new features were presented to the departments and evaluated as a team.” Project progress was visible to all stakeholders, creating transparency and acceptance. “This approach also allowed us to respond more flexibly to departmental change requests, leading to better, more practical results. Agile methods are now firmly established at Elkamet.”
Julia Günther is very satisfied with the collaboration with ORAYLIS: “It was true teamwork on equal footing, based on mutual trust. Through intensive training and support from ORAYLIS, we were able to develop solution components independently at an early stage. This enables us today to maintain and further develop our MDWH infrastructure independently.”

Solution Increases Machine Efficiency and Reduces Production Costs

“Through the resulting measures, we increase the efficiency of our production while simultaneously reducing costs,” says Marcus Schneider, Head of Production Planning at Elkamet.

In daily operations, the new solution brings multiple improvements. “Through centralized reporting, our production staff now have access to daily analyses that allow them to assess their area at a glance,” explains Marcus Schneider. Production managers and process optimizers can also use ad-hoc analyses to gain deeper insights into potential weaknesses and the causes of disruptions. “The resulting measures continuously improve our production efficiency while reducing costs. At the same time, our customers benefit from shorter delivery times and higher product quality.”
The Elkamet team can also independently create new reports with Power BI as needed. For example, new content is currently being developed for sales, enabling more targeted and ultimately more successful sales activities. “Above all, we are pleased to have found a competent partner in ORAYLIS, who takes the time to understand our requirements and supports us in developing suitable solutions,” concludes Julia Günther.

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