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Digital Twin Platform

Digital Twin Platform

The main benefit for users of Qlector Leap when implementing our digital twin technology is the ability to optimize and streamline operations in real time, leading to increased efficiency, reduced downtime, and improved decision-making based on accurate, data-driven insights.

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DIGITAL TWIN OF ALL LINES & SITES

Data Driven Replicas of All Production Lines and Sites

Digital twins as virtual replicas of physical production processes are the foundation of smart manufacturing. They enable users to simulate, analyze, monitor, guide, and optimize systems in real time. Along with artificial intelligence and machine learning, they accelerate and improve the performance of physical assets by analyzing complex data sets and dynamically adapting decision making in manufacturing.

Learning of Realistic Production Times

Based on historical data, we learn the actual production times and routings and suggest more realistic future production times than those set by fixed (static) norms. This enables the comparison of master data norms with actual production metrics, keeping the company’s master data up to date.

Simulations and Updates of Production Plans

Our Qlector Leap solution uses hundreds of predictive models to perform simulations and update production plans. We capture data from the shop floor and continuously update, learn and adjust the data on realistic production times accordingly.

Optimization by Key User Criteria

Using advanced AI optimization methods, we prepare the most optimal production plans based on key user criteria such as intermediate inventories, tool setup times, and customer prioritization, ensuring streamlined operations and high productivity.

DIGITAL TWIN CREATION

Building Models and Knowledge Graphs

We create a data-driven digital twin of all production lines and sites by learning and building models and knowledge graphs from data that comes from MES and ERP systems. We empower production and supply chain planners and team coordinators to create optimal plans and maintain lean production, closing the gap between production planning theory and shop floor reality.

CALCULATING TIME

Predicting Production Times

We use AI and the digital twin of the factory to predict how much time it will take to produce all products, to identify potential problems, and to suggest alternative routings if unplanned events occur (such as standstills).

DATA INTEGRATION

Merging ERP with MES & Keeping Master Data Up-to-Date

By merging ERP data with production data from MES and other related systems (APS, SCM solutions), we enable users to compare standard guidelines (norms) from master data with actual production metrics. This comparison aids in identifying anomalies and continually improving the accuracy of the company’s master data.

Use Cases

DISCRETE MANUFACTURING | AUTOMOTIVE INDUSTRY

Saving 3 Days a Week for Team Coordinators and Production Planners

Challanges

Manual planning consumed significant time, leading to inefficiencies and errors | Schedule adjustments required extensive phone and email communication, causing delays | Key knowledge was limited to a few people | Slow response to…


Benefits

  • 3 days/week  saved for planners
  • 25%  reduction in downtime with forecasting issues 3 days ahead
  • €300.000/year  saved in costs
Discover how Qlector LEAP optimized the production planning, scheduling, and guiding processes for a leader in discrete automotive manufacturing, with over 5.000 employees and €1.1 billion in revenue.

DISCRETE MANUFACTURING | ELECTRONICS INDUSTRY

Leap to Advanced Production Planning and a 25% Decrease in Downtimes

Challanges

Managing a wide range of products required extensive planning | Frequent schedule adjustments for recipes, product changes, and cleaning added complexity | Implementing Just-In-Time (JIT) delivery was difficult due to unpredictable demand…


Benefits

  • 75 hours/week  saved for planners
  • 25%  less downtime with  10%  improvement in JIT production
  • €220.000/year  saved in costs
Discover how Qlector LEAP significantly improved production planning capabilities for a leading electric motor manufacturer, employing 1.200 individuals and generating 200 million EUR in revenue.

DISCRETE MANUFACTURING | AUTOMOTIVE INDUSTRY

Reducing Lead Time by 10% for a Multinational Discrete Manufacturer

Challanges

Rising wages increased financial strain | Managing 2000 products and 1500 daily work orders added planning complexity | Long, unpredictable lead times delayed demand fulfillment | Manual labor scheduling was error-prone | Excess inventory…


Benefits

  • 10%  reduction in lead times
  • €135.000  annual savings from increased efficiency
  • 0.5 hours  saved per worker through improved task allocation
Discover how Qlector LEAP enhanced production for a prominent multinational company in discrete manufacturing, resulting in significant cost savings, improved operational efficiency, and agility.

PROCESS MANUFACTURING | FOOD & BEVERAGE INDUSTRY

Achieving a 5% Increase in OEE for an Austrian Food & Beverage Supplier

Challanges

Last-minute order changes led to inefficiency | Scheduling was hindered by bottlenecks | Failed attempt to digitize scheduler knowledge increased company risk, highlighting the need for a more robust solution


Benefits

  • Extended scheduling horizon by  3 days
  • 1-2 days  saved in planning
  • 5%  increase in Overall Equipment Effectiveness (OEE)
Discover how Qlector LEAP helped a food and beverage manufacturer with 9.000 employees and 14 production lines overcome scheduling and planning challenges, boosting production efficiency.

PROCESS MANUFACTURING I CHEMICAL INDUSTRY

Implementing Fast “What-If” Predictive Simulations at Paint Producer’s Plants

Challanges

Inefficient schedules caused frequent issues | Manual scheduling was time-consuming and error-prone | Complex product levels made planning difficult | Knowledge bottlenecks posed continuity risks | Seasonal fluctuations complicated resource and stock…


Benefits

  • 50%  Significant Time Savings
  • 20%  Decrease in organizational downtimes
  • Moving from daily to weekly scheduling
Discover how Qlector LEAP improved production efficiency and reduced downtime for a paint manufacturer with 460 employees and 31 production lines of varying batch sizes.

We are SAP Silver Partner

QLECTOR LEAP integration now works seamlessly out of the box. SAP, the market leader in enterprise application software solutions, empowers companies of all sizes and across various industries to operate at their best.

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With QLECTOR LEAP, we have digitally mapped every process within our company, revolutionizing our operations. This allows us to swiftly and efficiently formulate our production plan, complete with auxiliary workstations. The true game-changer lies in the plan's automatic updates. Simultaneously, all subsidiary processes remain informed of any modifications

By bidding farewell to a multitude of Excel files once essential for production planning, we not only declutter but also reclaim valuable time. The era of manual updates is now behind us.
I wholeheartedly recommend Qlector Leap to those who have yet to establish a systematic production planning system and still rely on Microsoft programs. The tediousness of handling such files and their susceptibility to errors can now become a thing of the past

Domen Škrbina

Head of Production Logistics at Kovis

Kovis is an internationally innovative company for the development and production of high-quality components for the railway industry and various parts for other industrial sectors. The company has established itself internationally with the production of brake discs for all types of railway vehicles: from locomotives, trams, and metro lines to high-speed trains. In addition to the brake discs, Kovis is also the largest manufacturer of axle boxes for freight wagons in Europe.
Kovis turns good ideas into a safe and sustainable future.

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QLECTOR LEAP has enabled significant progress in production plan optimization, as it learns from historical data, optimizes the plan, and provides more optimal suggestions for planners and production.

The most useful functionalities include real-time inventory overview, scheduling of workers and tool changes, and a user-friendly experience for planners, who receive a Gantt chart and a real-time overview of weekly realization. Any changes made to the plan in SAP by the planner are immediately visible in LEAP, allowing us to see when we will have reconfigurations and reduces tool change time.
The condition for using QLECTOR LEAP is well-organized data. With this condition met, LEAP operates with great precision, which is why I would recommend it to other manufacturing companies.

Marija Golja

Production Planner at Kolektor

Kolektor is a global supplier that boasts a tradition of highly specialized industrial production. In almost 60 years of experience, the company became a global provider of mobility components and systems and has added programs outside the automotive industry in the process of diversification and globalization and has spread to other continents.
Kolektor is a synonym for credibility, trust, quality, and innovative products and services. The programs are managed in three strategic groups: Kolektor Mobility, Kolektor Technologies, and Kolektor Construction.

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Qlector's software optimizes production planning in a simple, intuitive way and opens up new optimization options in a simple form thanks to the AI algorithms and various evaluations and reports. A must for modern production

Ingo Hild

Plant Manager at ams OSRAM Group

ams OSRAM is a global leader in innovative light and sensor solutions, building on over a century of experience. Combining engineering expertise with global manufacturing, the company delivers groundbreaking applications that make the world safer, smarter, and more sustainable. Specializing in high-quality semiconductor-based light emitters, sensors, and software, ams OSRAM continues to push the boundaries in illumination, visualization, and sensing across diverse industries.

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QLECTOR LEAP has enabled the automation of planners' work, faster response to changes in production planning, and management of a larger number of machines.

The results are currently evident in shorter inventory lead times for binding unfinished production and semi-finished goods, where we observe a 10% improvement. I would also highlight the expertise and agility of the Qlector team in terms of understanding and adapting to our production planning peculiarities. Domel follows modern trends in digitization, which is why QLECTOR LEAP seamlessly integrates into the ERP and MES system and is certainly one of the AI integrated APS solutions worth exploring.

Matjaž Roblek

Supply Chain Director at Domel

Domel is a global development supplier of electric motors, vacuum motors, blowers, and components. The company was founded in 1964 and has production facilities in Slovenia, Serbia and China. Their motors power over 300 million appliances in premium and consumer markets worldwide. Domel’s business processes employ high levels of technology, automation and robotisation, which form a basis for building competitiveness and excellence.