'Fleximatize'

At TechNikkels, their motto is "fleximatize. Automation, but flexible. They develop and build machines for feeding, filling and sealing bottles, jars and (jerry) cans and American folding boxes - and then specifically for companies that process a wide variety of them. Partner for their automation needs is Lenze.

Director and founder Henk Nikkels has earned his spurs in specialty engineering at a few large industrial companies. He started TechNikkels in 2003 and began developing his own filling and packaging line in 2011. By now, a mature company stands and is fully committed to servitization. "Whereas the focus was initially primarily on building high-quality flexible machines, it has now expanded to include making sure customers get the maximum return from our machines. Because we operate locally in the Netherlands and Belgium, we can also respond very quickly to questions. Preferably we do that remotely, but if necessary we are quickly on location. In five years, things may look different and we will be able to serve new markets more easily, because by then we will have further developed remote support with all available tools."

Efficiency is the key

TechNikkels' machines fully automate various operations in a packaging process. Think of feeding the packaging, filling, sealing and packing in a box. "Not only the shape and size of a package can be very diverse, but also the material used and the margins on the thickness of that material," explains Thijs Krijgsman, manager of sales and service at TechNikkels. A transparent plastic bottle processed at high speed on a machine is being tested. "We don't just want to deliver a machine or a line, but also an optimal performance of that machine and a smaller carbon footprint. This means that we also advise and develop proactively in the field of monitoring." Industry 4.0 and digitalization can support this. One example is the creation of dashboards for OEE improvement. "We have a lot of data at our disposal with which we have input for further development and optimization. The data coming out of the machine is purely factual. So you can analyze production and see exactly where you can improve. You underpin your OEE with objective data, so to speak. Because the goal is not to tell customers how to do it, we provide tools to focus on the right things." 

Flexibility

TechNikkels' flexibility manifests itself not only in the types of packaging a machine can process, but also in how it is used: operating, diverting, controlling ... "Our machines are designed specifically for a wide product range, which is our differentiator," says Krijgsman. "That's why all our machines are super-fast or even fully automatic changeovers. Today, batches are often small and product life cycles short. Being able to change quickly and easily without error is a real must. Everything is aimed at making the line easy to operate, also with a view to staff turnover, actually anyone can operate this machine." Nikkels explains that "everything in the machine is aimed at variation. Per process we choose the right technology, like when placing bottles in the box. In doing so, we try to use as many components as possible from a single source, so that everything is already coordinated in the base." 

Remote

For remote delivery of support and condition monitoring, the PLC takes on the role of the gateway to the outside world, so to speak. The PLC becomes actuator and communicator. Lenze project Stefan van Dooren explains how this works: "All data is displayed in a dashboard. That gives real added value, because everything is aligned, it really is an end-to-end solution. And with the dashboard, you have a great tool for OEE monitoring." Krijgsman adds: "Showing numbers is not the trick. Information and context, that's important. Customers want dashboards that are as simple as possible, that present the information clearly and can be read by anyone. We ask the customer what information is important and build a clear dashboard, based on the customer's wishes, with objective information. A production manager can do something with that." Nikkels sees more opportunities: "The HMI can be a distinguishing factor for the operator's job satisfaction. But for us it is important that we can achieve less downtime because we can watch remotely. That way you can provide very quick support in the event of a downtime."

Maximum support

Another example passes muster. In 2014, TechNikkels built a large specialty machine for wrapping gift paper. And at the same time, the company already had an order running for a large line. "Then it became a matter of operating smartly. Because both orders had a very short lead time and then you don't just pull out a can of people. For the controls of those two orders we contacted Lenze. And we found each other immediately. We received maximum support to get these two projects through in the desired time. That was in the beginning of our collaboration and I must say, we are super happy with Lenze as a partner. Both on the automation side and on the operational technology side. We have done quite a few projects together in the meantime and we are very satisfied."

Management of your installed base 

So that OEE is fine. But asset management also benefits from objective data and information. Daan Nikkels, responsible for service business development at Nikkels "If you can keep track of the installed base, you can build in learning capability with a history of questions and incidents. All inspections are insightful, in short the entire history of your installations. We are conducting a pilot with Lenze, where customers send all questions to us in one portal. Very accessible, but it only works if the customer also embraces the new solution." Van Dooren is the project leader for the pilot on behalf of Lenze: "From the platform we can offer remote maintenance, log all information about failures, for example, but also all documentation is stored there. Everything centrally with a comprehensive historical overview." The developments are going full speed ahead. Nikkels: "Automation will become increasingly important. Not just to save costs, but out of sheer necessity, because you have to be able to work with fewer people on a line. There is a scarcity of people, resources ánd materials, and then it is very nice if your supplier is close by, that is a real plus."