Andea partnered with Magna to:
Accelerate system performance to meet the demands of JIS production.
Ensure reliable, real-time support from a provider in the same time zone.
Collaborate with a trusted partner with proven experience using the DELMIA Apriso platform.
The manufacturing process at the Heilbronn facility divides the underbody into three parts—rear, middle, and front—each built separately and assembled on the main production line.
Magna’s operations rely on the Just-In-Sequence (JIS) production method, where every production line operates in strict synchronization. This approach minimizes inventory but leaves little margin for both delay and error. Any stoppage on one line risks halting the entire facility.
Maintaining seamless production requires constant monitoring and immediate issue resolution, both of which are possible using specialized software, configured to specific shop-floor processes. In Andea, Magna found a reliable partner with deep expertise in DELMIA Apriso, a leading Manufacturing Execution System (MES).
Before reaching out to Andea, Magna faced performance challenges with its DELMIA Apriso system. Slow database response times frustrated users, making it difficult to synchronize, monitor, and execute tasks efficiently. The whole production process was getting increasingly more difficult to harmonize and control.
The automotive supplier decided to seek an experienced partner able to improve responsiveness to issues while meeting Service Level Agreements (SLAs). Since Magna had previously collaborated with Andea on a database archiving project, the company decided to reconnect and see if the two organizations could join forces once more.
At that point, Magna’s expectations of a DELMIA Apriso provider encompassed:
Ensuring faster system performance to meet the demands of JIS production, streamlining synchronization across all production lines.
Delivering reliable, uninterrupted, and real-time maintenance support, with dedicated specialists working in the same time zone and available during the plant’s key operating hours.
Bringing a proven track record as a renowned DELMIA Apriso integrator and service provider, with a portfolio of successful global projects completed for top clients.
The successful outcome and good relationship during the previous stint made Andea the ideal choice for this reestablished partnership. The two teams worked closely to address the current situation and solve the system’s performance issues.
Andea introduced several key solutions.
Removing outdated records from the DELMIA Apriso database to optimize storage and improve overall performance.
Managing all aspects of database administration, including parameter adjustments and implementing performance improvements such as indexing. These changes reduced query times from minutes to mere seconds, significantly accelerating the system’s responsiveness.
Working between 6 AM and 9 PM to align with Magna’s factory hours. These operations hours ensured rapid incident resolution, minimizing the risk of production downtime. While the SLA allowed up to four hours for issue resolution, the team consistently resolved incidents faster, keeping all production lines operational.
Creating Excel-based reports with 274,000 order records from 2016 to 2024. This solution enabled Magna’s business users to access a huge backlog of historical data instantly, even when the database was offline.
Monitoring and optimizing database performance daily to prevent potential bottlenecks and ensure seamless and fully synchronized operations in a highly dynamic production environment.
During this second stint, Magna and Andea once again proved there was great chemistry between the teams, ensuring a smooth and productive collaboration. With both parties demonstrating a can-do attitude, the successful outcome quickly turned from goals to tangible results. Magna achieved all their objectives, including:
A substantial improvement in the DELMIA Apriso system performance, significantly reducing query times.
Reliable real-time support that prevented production downtime.
Enhanced data management, ensuring seamless access to historical and current information.
On top of that, Andea’s specialists solved the pressing issue of the naming convention in DELMIA Apriso’s Machine Integrator. Moreover, all of Magna’s documentation being in German posed a serious challenge in a globally interconnected manufacturing environment. Despite the complexity of such an undertaking, Andea succeeded in translating the existing documentation into English.
Andea’s expertise in MES solutions and unmatched dedication to client success ensured Magna’s JIS production lines operated without interruption. This lasting partnership underscores the importance of developing mutually beneficial relationships based on reciprocal chemistry and mutual trust. With years of successful MES implementations, unmatched maintenance support, and experience working across time zones, Andea has proven to be the right partner for manufacturers seeking support at any stage of their projects.
We are highly content with all the work and the designed solutions. Andea’s knowledge of the DELMIA Apriso platform, combined with reliability and a professional approach left a lasting impression on everyone involved here at Magna.
Our goal was not only to improve the performance of Magna’s DELMIA Apriso system while ensuring seamless JIS operations but also to continue being the trusted partner they knew we were. This collaboration highlights the value of proactive maintenance and tailored solutions in high-stakes manufacturing environments. It also demonstrates that having a great relationship goes a long way.
