Wilo's smart factory sets standards in digitalization

“It is important that we continue on this path because there is always more to achieve,” said plant manager Branko Calusic when Wilo's Smart Factory in Dortmund won the award in the 'Digitalization' category in 2022. It was clear to Kearney that significant steps followed this resolution. Thus, the plant was able to achieve another milestone through consistent site development focusing on the key factors of communication and transparency, holistic improvement, competence management, and leadership: the overall victory at the Factory of the Year 2024.

In addition to expanding the company headquarters Wilopark, significant progress has been made within the Smart Factory itself. Not only in the area of digitalization. “As part of the site development, we have launched clear offensives in the last two years to really involve everyone in different topics - from the executives to the employees on the shop floor,” Calusic describes the essence of a transformation.

An example of such an offensive is the implementation of so-called sustainability ambassadors within the individual departments. “Sustainability, like quality or digitalization, is not limited to one department but affects everyone,” explains Calusic. The task of a sustainability ambassador as a link between employees and departments is therefore to sharpen and broaden the understanding of sustainability.

Employees are at the center of the strategy

In the area of sustainability, the manufacturer of pumps and pump systems for building technology, water management, and industry also places its employees at the center of the strategy. Therefore, the overall winner invested in both the Health Cube, its own health center at Wilopark, and accident prevention within the winning plant.

“In terms of occupational safety, it's not just about the well-being of the employees, but also about reducing errors and downtime accordingly. That's why we created Safety+, a way to mark danger spots on the digital area boards by touch,” says Calusic, naming one of many shopfloor initiatives.

If a near-accident or similar is marked on the digitally mapped shopfloor, it is immediately forwarded to the appropriate occupational safety committee, which can then take appropriate measures. “Here too, the goal was to involve everyone, which is why we have received up to 400 tips through these boards in the last two years,” the plant manager is pleased with the user-friendly and effective way to increase safety in the plant.

Support through the use of artificial intelligence

“That we also focused on the shop floor with our various initiatives was important and right to take everyone along the path to an even more digital, sustainable, and flexible future,” explains the plant manager about the measures. This is also supported by the use of artificial intelligence.

Calusic cites an example from electronics manufacturing, where AI was able to reduce the pseudo-error rate of an AOI system: “We optimized the system to the point where only about 0.5 percent are judged as pseudo-errors. About half of them actually are.”

Wilo also relies on AI for checking sealing beads: sealing beads only adhere properly if the mixing ratio of the components is correct. To avoid corresponding failures, artificial intelligence checks the adhesion using thermal images. In addition to checking adhesion, the system is also capable of making statements about the optimal mixing ratio so that the sealing bead adheres permanently.

From the beginning, it was important to the plant manager to involve the employees from the shop floor in all the initiatives. For example, with the gamification of digital worker guidance. “For this, a standard worker guidance system was further developed into an adaptive system that adjusts the support to the level of the worker,” he explains.

Someone performing a task for the first time is shown significantly more content about the individual work steps than an experienced specialist. Essentially, you can work your way up or down to a level if the activity hasn't been performed for a while.

Such tools also serve Wilo to fully exploit the existing potential. This is exactly what needs to be worked on, because Calusic is convinced that recruiting should not be the only way to compensate for the shortage of skilled workers. “So, for example, in the last four years, we have trained nearly 60 people in the area of Six Sigma. From White Belts to Master Black Belts, to really reach the masses.” To engage with the Scrum method, a Scrum Master with appropriate job rotation was brought into the company. The people who are in this group for six months at a time and solve problems for logistics, sales, or purchasing in a team have a completely different perspective on the topics when they return to their day-to-day business because they know the big picture.

The potential mentioned by Calusic can be significantly enhanced, as shown by the fact that half of the 'returnees' take on new tasks because this experience provides them with new opportunities. The other 50 percent return to their jobs as better employees. "In recent years, we have been able to build extremely high-performing teams that do not hide, constantly step out of their comfort zones, and are willing to go the extra mile for the company and their own development. Most are open to new things, understand the necessary changes of our time, and are proud to be part of Wilo. And I feel the same way personally," announces Calusic.

Flexibility is one of the key factors for the future

Of course, the victory two years ago motivated the team and confirmed that all the changes brought success. "In the end, it's about not stopping too soon, but also taking the final step," says Calusic.

And so, the overall victory in the Factory of the Year 2024 is not the end of the road for him, but a snapshot. "We still have a long way to go," says the plant manager regarding the complexity that lies in the interfaces. "Improvement processes are not limited to one department. You have to involve purchasing just as much as planning, logistics, production, and process engineering," says Calusic about the interdisciplinary exchange, for which a dedicated area was even created with Holistic Improvement.

"Creating this transparency for the orientation of the individual areas is extremely important because we will always be working on small puzzle pieces. And when people understand where their small picture fits into the big one, a completely different dynamic, a different motivation, and a self-understanding for these topics emerge," describes Calusic the impact on the overall package, with which Wilo was clearly able to convince the jury this year.

Confirmed by the neutral judgment, Wilo will consistently continue on the chosen path and aims to become even more determined and flexible, as flexibility is one of the key factors for the future to be able to adapt to the constantly changing situations.