ERP for CLT

Three years ago, Theurl opted for a uniform ERP system from Timbertec of Eutin/DE which the company wanted to use for all processes – from log wood purchasing to fully automatic glulam order picking. In one fell swoop, almost all of the existing stand-alone solutions were replaced and all data were merged into Timber Commerce (TiCom). “Following our positive experience, especially when it comes to the interplay between TiCom, work preparation and the system control of the glulam order picking crane, we contacted Timbertec again when we were planning our CLT plant,” IT expert Roland Theurl tells us and adds, “Timbertec already had numerous suitable solutions ready. Also, some new developments, such as the production simulation or the interface to Hundegger’s Cambium software, were implemented according to our wishes.”

A few years ago, Timbertec expanded its TiCom system to include a module developed specifically for the production of cross-laminated timber. “This allows us to control the entire production process from incoming orders to shipping, which results in a significantly faster and more efficient processing of orders,” Timbertec Managing Director Andreas Boll explains.

Fully automatic warehouse

The approved joining files in BVX format are the basis for the entire production planning process. With the help of this information, each order is entered into the ERP system and added to the production database after work preparation. At Theurl, this database was separated from the ERP system for the first time and now works largely autonomously. “When there was no internet connection for several hours shortly after the system was booted and production was unaffected by it, we knew that this additional effort was worth it,” Theurl says. The Steinfeld production site is located over 50 km west of the parent site.

Once a batch has been transferred from the TiCom system, the operator can start the order via a web-based client. “In that moment, our system sends the data to the Microtec master computer and production begins,” Florian Weidinger from Timbertec explains.

A Voith overhead crane is used for the fully automatic raw material infeed and the entire warehouse management. Controlled by TiCom, it fills and empties the warehouse, which uses a random storage system, according to the required raw material in the started production orders. “With a visualization tool that we developed for the warehouse, we can check the inventory at all times and usually, we don’t have to intervene in the warehouse management and the infeed,” Weidinger tells us. “Due to the many interfaces to different programmable logic controllers, the exchange of data has to work perfectly. For me, it was a positive surprise that this part of the start-up worked, too, despite the adverse circumstances,” Theurl adds. Due to the ongoing pandemic, Timbertec did a remote start-up of most of the system control. The work preparation modules in the ERP were even put into operation completely remotely.

Visualization optimizes the production flow

For Theurl, another special feature of the project is the visualization of the entire production process – from the above-mentioned stock levels and the laying of the single-layer panels to the storage towers for the finished elements. “With this information, which is generated with the ERP system, an optimized production flow is calculated and simulated fully automatically according to the specifications of the machines, thereby enabling the work preparation team to optimally plan and feed production. This way, we can continue to optimize the production flow and, by using a flexible selection and subsequent calculation of laminations, it’s easy to plan everything according to the availability of the raw material while reducing waste at the same time,” Theurl explains.

Everybody knows everything

Behind the panel press, another Voith crane controlled by Timbertec takes over the elements by means of a vacuum lifter and transports them to up to 5-meter-high storage towers in a free storage area or to the patching station. There, the employee can retrieve all data about the panel in front of them with the Timbertec web client and take the data into account when processing the panel. “Via the nesting, which is done with the TiCom system, the employee can see exactly what is cut from each panel and can adapt the repairs and sampling accordingly,” Weidinger tells us.

Thanks to the close link between the production database and the ERP system, the sales representative knows the production status of each individual element at all times, which allows them to coordinate deliveries with the customer. “Each of our employees knows where the panels are. This saves us a lot of time and makes communication with customers easier,” Theurl says, explaining the advantages of the web database which was a first for Timbertec in terms of its scale.

Successful project

A joinery employee orders the individual panels, which can also be sanded in advance, from the storage area with a click of the mouse. Thanks to the newly programmed interface to Hundegger’s Cambium software, the elements which are to be processed can be retrieved and edited again if necessary, and employees can see at a glance what needs to be done and what the finished elements should look like.

After joining, printed labels are attached to the panels for a clear identification and the panels are provided with all the necessary information, after which the finished order appears in the TiCom system.

One year after the start-up, Roland Theurl, who is responsible for the project at Theurl, is more than satisfied. “Despite the numerous special solutions and the difficulties caused by the coronavirus pandemic, everything went very well. Timbertec worked very hard.” A compliment which Weidinger returns: “The more the customer helps us, the faster we are. Working with Theurl was a walk in the park.”