Domus Line, the holistic factory 4.0

26/03/18

We tell you our project of holistic factory.

In the last two years, Domus Line has undertaken a major restructuring of its production and logistics system. The process has brought about an in-depth renewal of the production site and logistics management. The aim was to increase productivity, efficiency and the level of the services offered to our customers in the more than 70 countries to which we export.

The first phase of the project involved the reorganisation of the production cycle on Lean Manufacturing principles, with the building of a new production department. The assembly stations were designed with an extreme focus on people and their well-being, in well-lit interiors, free from noise and dust, with a controlled temperature microclimate maintained by a constant air filtration and ventilation system.

Equipping every workstation with a tablet with direct access to the company Data Cloud enabled the complete reorganisation of production management. Material flows were also redesigned in accordance with a holistic view of the factory. A Lean Thinkingapproach provided the basis for labour-saving smart handling, and the payback period was completed just a year after the start of the project, with an average cycle time reduction of 15%.

The second phase of the project concentrated on reorganisation of warehouse management, with introduction of smart label transponder technology to identify goods and automatically store the information relating to them and their handling. The new RFID(Radio-Frequency IDentification) system improved the efficiency of operations with a 50% reduction in shipment preparation times and totally guaranteed packing lists.

The final phase involved an area of strategic importance for the company, crucial for all manufacturers operating at the international level: supply chain management. To meet the challenges of a more and more dynamic, demanding market, during the last few months Domus Line has decided to adopt a new procurement management system called DDMRP – Demand Driven MRP. Domus Line will be the first company in Italy to implement this new solution in its ERP.

Products with constantly evolving technologies and reduced life-cycles, shorter lead-times and extremely customisation have made conventional requirement planning systems obsolete. The Domus Line supply chain is now sales-led and no longer focused on maintaining inventories at safety levels. A system that allows intensification of the customer focus, through dynamic, integrated analysis of orders and material stocks.

The quality of Domus Line’s processes is supported by an integrated system covering environmental sustainability, occupational health and safety, social responsibility, intelligent administrative management, accurate risk assessment and, naturally, continual striving for the maximum customer satisfaction. Constant investment in change is in our company’s DNA, and a new project is already under way to increase the digitisation culture in sales and marketing processes as well, together with an ambitious programme for global certification of the entire product range.

The project was partly funded by the European Regional Development Fund (ERDF ROP) 2014-2020 “Investment for growth and employment”, co-funded by the European Union (European Regional Development Fund), the Italian Government and the Region of Friuli Venezia Giulia. The objectives of this European programme are many: strengthening research and technological development and innovation, improving access to information and communication technologies (ICT)and promoting the competitiveness of small and medium-sized companies. Domus Line used the financing to activate and implement a state-of-the-art technological and logistic renewal process.