Nonwoven is much more than just a fabric today. Industrially produced and processed in numerous markets such as the automotive or construction or medical industries, such products are used for a wide range of purposes. Nonwovens are suitable for producing hygiene products such as baby diapers or wound dressings, as well as for applications in the automotive industry (e.g. sound absorption, padding, and floor mats) or in the construction industry (e.g. sealants or carrier materials). Special attention should be given to the production of Vileda’s well-known cleaning cloths, textiles for bulletproof vests, and brake shoes on Dilo equipment.

The DiloGroup’s core competence lies in the production of complete solutions for needlefelt with the highest production speeds and nonwoven qualities ranging from fluffy and soft to highly durable — as documented in a multitude of patents. The group consists of DiloSystems, the specialist in plant engineering, and the machine and plant manufacturers DiloTemafa for opening and mixing components, DiloSpinnbau for mechanical and aerodynamic nonwoven formation, and DiloMachines for nonwoven laying systems and needling machines.

Every Square Meter Counts

Nonwoven production is a complex process in which a wide variety of parameters can influence fiber processing and product quality. The systems, some of which operate 24/7, must be reliable — a challenge Dilo succeeds brilliantly. The digital COSCOM ECO-System makes a significant contribution to this success by ensuring seamless coordination of parts production on the shop floor.

Speaking of manufacturing: Dilo is a true machine and plant manufacturer. Most of the parts are produced in-house. This is because a high degree of vertical integration offers great flexibility, for example when it comes to implementing further improvements to components as quickly as possible.

At Dilo, the COSCOM ECO-System, integrated with the SAGE ERP system, guarantees 100% reliability in production orders. The COSCOM ECO-System consists of the COSCOM modules ProfiCAM VM (Virtual Machining) for CAM programming, ToolDIRECTOR VM for tool management, and FactoryDIRECTOR VM for technology data management.

ERP Integration with FactoryDIRECTOR VM Puts an End to Duplicate Data Management

The COSCOM ECO-System is directly connected to Dilo’s leading ERP system, for good reason: “This integration eliminates the need for duplicate data management,” explains Ralf Fürst, Head of Mechanical Manufacturing, with satisfaction, adding: “Data consistency all the way to the machine tool is a particular advantage of our COSCOM installation. This significantly increases efficiency and prevents sources of error.”

The design department creates the parts master with the part name directly in the ERP system, and each department adds further metadata. Finally, the data record for production is finalized in production planning. The part designation often makes it possible to identify which area of production planning is involved. “A marker in the ERP system initiates the data transfer to the FactoryDIRECTOR VM. In the FactoryDIRECTOR VM, the user can intuitively add further order characteristics to the item master, such as the number of operations,” explains Ralf Fürst.

Everything Revolves around COSCOM – in Manufacturing

“We’re open to using new tools and new manufacturing strategies. For example, solid drilling with internal cooling or solid carbide drills. These tools are purchased, assembled upon delivery, and simultaneously entered into the ToolDIRECTOR VM,” says Ralf Fürst. This ensures that the entire process chain is digitally mapped in a closed-loop system.

The ToolDIRECTOR VM is connected to a tool measuring device of Zoller. Digital twins of the tools are synchronized. The goal is to map the entire tool lifecycle — from purchasing, through use on the machines, to regrinding by a service provider, and back into inventory — so that, for example, tool discrepancy lists can be generated.

Digital Natives and Digital Immigrants Working Together

Ralf Fürst is very proud to have recruited an experienced expert for the new tool management system. “This colleague knows exactly where every drill is located and which indexable insert needs to be installed. I’m very happy to have been able to get him excited about the new world of digitalization with COSCOM. By now, he can’t imagine working without the ToolDIRECTOR VM. This is proof of how intuitive the management tool is to use,” emphasizes the production manager. At first, there were concerns, but the employees quickly realized, Ralf Fürst continues, the enormous potential of the COSCOM ECO-System and what this means in terms of making work easier: “We no longer have any tools in circulation that haven’t been saved in the ToolDIRECTOR VM beforehand.”

Understanding of Digitalization Needs to Mature

Ralf Fürst worked in production planning for 25 years and has held a management position in mechanical manufacturing for quite some time. His close collaboration with Dirk Boothe, Area Manager at COSCOM, based in Ebersberg near Munich, and the deep integration of COSCOM solutions have sharpened his understanding of the efficiency potential inherent in consistent digitalization. His first contacts with COSCOM date back as far as 1990. A good four years later, ProfiCAM VM was installed for the first time. Starting in the early 2000s, the first machines were connected, and beginning in 2014, intensive discussions with Dirk Boothe focused on the fully integrated COSCOM ECO-System. In 2015, the company began working with 3D-axis milling incl. CAM, and in 2016, machine simulation was added. And in 2021, the time had come: the company made the transition to the COSCOM ECO-System with FactoryDIRECTOR VM, ToolDIRECTOR VM, and the terminal solution InfoPOINT VM. Most recently, the SAGE ERP system was connected to FactoryDIRECTOR VM.

A total of 17 machining centers are in operation on the shop floor, with the controls of two machines connected to the COSCOM ECO-System for bidirectional data exchange. All Mazak, Siemens, and Heidenhain controls can be programmed with ProfiCAM VM. “COSCOM supports various protocols, such as Ethernet and RS232, to communicate with the machines. In fact, we can provide the necessary information not only for newer models but also for older machines,” says Dirk Boothe.

Dilo’s manufacturing division employs 47 people, including two full-time programmers and another employee who is well-versed in using the COSCOM ECO-System.

The increased efficiency of working with the COSCOM ECO-System is clearly demonstrated by a crossbeam, a large steel structure (weighing between 3.5 t and 20 t!). Experience has shown that two to three machining operations with different CNC programs — sometimes requiring different clamping techniques — are necessary for a single machine. Such details are immediately stored in the COSCOM ECO-System and are thus fully accessible.

“We record machining times down to the minute, but billing isn’t done at that level of detail.” Ralf Fürst does not wish to comment specifically on the potential savings of the COSCOM ECO-System, as it has not been in operation at Dilo long enough; however, one point is already clear: “We are now able to analyze very precisely which measures will allow us to maximize internal value creation.”

The decision to choose ToolDIRECTOR VM and FactoryDIRECTOR VM was based on the positive experience gained from the long-standing partnership with COSCOM. FactoryDIRECTOR VM was introduced in early 2022.

Safety and Confidence

It’s always the numbers that count. The digitization of the setup sheet using FactoryDIRECTOR VM has been a tremendous success. This has reduced the workload from 100% (paper-based workflow) to 10%. Whereas creating this overview used to take two to three hours, today it’s done virtually at the push of a button. “But the biggest advantage is that the machine operators have access to all the information they need for their work: simulation data, tool data, and information for retooling. This creates safety and trust. This is all the more important because we sometimes machine very capital-intensive parts,” says Ralf Fürst.

Conclusion: Professionals Driving Digitalization at the Plant

For younger employees, end-to-end digitalization is a matter of course — even on the shop floor. This is essential for remaining an attractive employer. But it is the older employees, in particular, who are the key holders of expertise. They, too, must benefit from the advantages of end-to-end digitalization. This is easy to explain in a conversation, but a comprehensive platform like COSCOM’s requires a somewhat different way of working that must be internalized. “I am very satisfied with the project management, which was led by Dirk Boothe. With a great deal of tact and sensitivity on COSCOM’s part, we have fully digitized our manufacturing,” says Ralf Fürst in conclusion. This has sustainably strengthened the DiloGroup’s competitiveness.