Alvon Bouwsystemen B.V. in New-Amsterdam manufactures prefab-concrete structures, such as prefab walls (translucent concrete, massif, hollow wall) and reinforced wide-slab flooring. Alvon works according to the just-in-time delivery principle: components are delivered on demand to the construction site in sequential order needed for construction. This keeps activities at the construction site to a minimum, which results in a lower cost price for the contractor.
The manufacturing method is very efficient and has been structured so that production lines and systems are fully in sync with one another. At the same time, the production system is very flexible so that capacity per product type can be increased quickly.

Technosoft Methodology

The first step was to map out the customer’s needs in detail. During the analysis we mapped out the entire logistics process (scanning drawing office data, recording assembly numbering, creating transportation lay-out, creating a general and detailed schedule for all components, managing production operations via files and production lists). This took place in close collaboration with the customer. The specifications for the solution were also recorded in detail during the analysis. Continuous feedback was provided during the software programming phase, whereby the components in question were implemented in phases.

Needs analysis

The customer needs a system that can efficiently manage the entire, just-in-time delivery process. This means that multiple users have to be able to access the same, clear information for accurate internal and external communications. It also means that the system must contain a number of powerful tools so that the user can arrange the prefabricated components in shipments based on assembly number and  that can be used to schedule the different product types automatically on the production lines (long line or tables). The system must also connect to the ERP system (Axapta), the customer’s drafting software (AlvonCAD)  and production can be managed through production lists and exchange files for plotters and laser equipment.

Vision behind possible solutions

Our vision was to ensure that Alvon Bouwsystemen B.V. could work efficiently with the aid of IT processes. The software had to be configured in such a way as to create a dynamic link to the existing drafting software (AlvonCAD), the ERP system (Axapta) and the production system, while using standard components where possible and setting up a solution tailored to this environment to match the organization and the needs of its end-users.

Chosen solutions

• We built a Windows application with a back-end database that fulfilled the global requirements for the following process:
• Scanning general project data, component data, systems for pouring concrete from a drafting system
• Using a graphical interface to record a lay-out plan of the component assembly sequential numbers for the components with the aid of powerful selection tools;
• Using a graphical interface (where the geometry of the components is also visible) to lay out the shipments semi-automatically, taking the different types of  trailers into consideration (crane, barrel, flat, standing or vertical or horizontal), the desired assembly sequential order and the specific component characteristics (dimensions and weights);
• Creating a global, weekly schedule for shipments based on pouring and delivery date (general scheduling), while separating the products per production hall;
• Scheduling the components for production automatically per day and per production hall, whereby both long lines and tables are scheduled, each with its own specific conditions;
• The position and the number of reinforced wires for the prestressed reinforced wide-slab can be easily recorded and calculated;
• Creating production lists (both graphics and text), component cards, picture books, verification forms, bills of lading, packing lists, inventory summaries, stock overviews and production files for plotters and laser operations;
• Processing different statuses per component, such as shipment schedule, production line schedule, manufacturing schedule, test data processed, etc;
• Exchange of status information per component with the Axapta ERP system with updates to the drafting system.

Advantages for Alvon Bouwsystemen B.V.:

• Data is only entered once into a single location, which makes the data clear and easy to access for all users;
• Linked to all relevant systems (ERP system, drafting software, production machines);
• The capability to record assembly numbers via powerful graphics tools;
• Semi-automatic transportation allocation, whereby the allocation can be optimized using the drag and drop tools;
• Automatic line and table lay-out, whereby powerful drag and drop tools can optimize the allocation (rotate, move, snap functions, zoom, etc.);
• Extensive reporting option
• A scalable and flexible application: It is easy to increase the number of users. The application can be customized by user and it contains a wide range of preference settings.