Inside HARTING’s Espelkamp Factory | Dr. Andreas Imhoff
HARTING is a global leader in providing industrial connectivity solutions, vital for various sectors including transportation, electromobility, renewable energy, automation, and mechanical engineering.
Recently, our Editor, Subhajit Roy, was invited for a tour of HARTING’s state-of-the-art factory located in Espelkamp, Germany!
During the tour, Subhajit had an exclusive interview with Dr. Andreas Imhoff, Managing Director Operations at HARTING Electric, where they delved into the heart of HARTING’s operations. They discussed the plant’s infrastructure, the diverse product line, impressive production capacity, cutting-edge automation technologies, energy efficiency measures, and the integration of artificial intelligence.
WATCH this interview as we bring you insights into HARTING’s cutting-edge advancements shaping the future of industrial connectivity!
Can you give a brief background of your factory and the products you make?
At our primary factory, we specialize in manufacturing heavy-duty connectors primarily for the machinery, wind energy, transportation railway systems, and data center industries. Our range of connectors is incredibly versatile, spanning from flexible and small-current options to those capable of handling huge currents. With a diverse array of a couple of thousand connector variants, we cater to a wide range of needs.
Can you provide details on the 52 variants you develop and the 23-step manufacturing process you use?
We have implemented a new production technology inspired by Henry Ford’s classical one-piece flow approach. With 23 processing steps, we efficiently manufacture 52 different variants within the same product group. Our machines autonomously handle setups, resulting in zero setup time and costs. This allows seamless production transitions between variants without added expenses. Whether producing one or 10,000 units of a variant, our system adapts effortlessly.
Can you explain the automated solutions and digitalization processes used in your factory to develop the 52 variants?
Our cutting-edge production technology is fully automated and digitally integrated, thanks to our partnership with Harting Applied Technology. This dedicated group pioneers new machinery and automation technologies, including bin picking and software solutions for our 23-step processing line. The software development process was as intricate as the hardware, spanning approximately three and a half years from conception to realization.
In your smart, digitalized factory, vast data generation is inevitable. How do you utilize this data and what types of big data analytics do you employ?
At our factory, we employ threshold applications to detect issues such as high compressed air flow, indicating potential cylinder defects or leaks, leading to significant energy savings. Additionally, we utilize tools on turning machines to monitor tool wear, enabling timely replacements and preventing unexpected breakdowns. Algorithms help us assess process stability and ensure consistency within desired parameters, detecting instabilities and quality issues early on. With our vision of a self-optimizing factory and ongoing development of digital twin technology, we anticipate substantial productivity growth in the coming years.
How does digital twin technology in your secure factory increase productivity and cut production costs?
At our factory, lean processes and digitalization go hand in hand. We believe in streamlining operations first and then integrating digital solutions for optimal efficiency. This approach enables us to accurately assess the effectiveness of new tools, monitor energy usage, and make informed decisions for the future. By prioritizing data transparency, we streamline processes and reduce effort, ensuring we always have the right tools for the job.
Does this process also aid in enhancing and preserving product quality?
Quality takes precedence over cost, serving as the primary focus in our operations. While it may be tempting to prioritize cost-cutting measures, we understand that maintaining high quality is essential. By integrating quality data and machine data, we can swiftly identify and address any deviations from standards, ensuring optimal performance. Our ongoing efforts include optimizing quality inspection processes, and moving away from manual methods to automated systems wherever feasible. This approach provides comprehensive insights into our processes, allowing us to make informed decisions based on real-time data.
In conclusion, we know that Harting has set multiple world records in your factory. Can you highlight some of these achievements?
We handle various processing steps such as aluminum and zinc die casting, injection molding, turning, milling, and powder coating. While our Turning Department boasts several world records in different aspects, we’re proud to maintain them as a testament to our achievements.
