The Company

3F Filippi S.p.A. has been operating in the lighting sector since 1952, with a solid experience in the design and production of efficient technical lighting systems. Its products, designed and manufactured exclusively at its plants in Pian di Macina, in the province of Bologna, proudly carry the Made in Italy label to more than 50 countries worldwide. Together with Targetti, another historic Italian lighting brand, it forms a group aiming to be a reference in technical and architectural lighting both in Italy and globally.

The Challenge

Replace the previous MES system to improve production monitoring and obtain more accurate and reliable data. Specifically:

• Introduce a more precise MES system for data recording and easier to use
• Eliminate paper documentation in production (e.g., setup instructions, safety procedures, assembly instructions, etc.)

• Digitize and improve machine and plant maintenance.
• Digitize the ICQ (Quality Control Insertion) process
• Have timely and reliable statistics on the main performance indicators (KPIs) of the production process.

Solution

The project involved modeling the production process to map collection points and configure procedures to ensure correct data acquisition while minimizing impact on operators. The implementation began in the areas where this activity was less structured, resulting in a significant change in the management and sharing of documentation. The Compass MES system is now used to “embrace” all elements and processes of production at 3F Filippi.

In summary:

• 3 factories,
• 13 departments,
• +30 terminals,
• +230 records,
• +100 machines,
• +100 operators,
• +130.000 pieces per day,
• 700h/work hours per day,
• +80 machines per day,
• +110 orders per day with cycles ranging from a few seconds to 40 minutes per piece or orders lasting from 4 minutes to 4 weeks.

The system, through more precise and timely data collection, is also used for documentation related to setups, quality control readings, and plant maintenance management. Finally, with the Power BI block, it is possible to generate reports with factory KPIs, which are immediately updated, with solid and shareable data.

Results

• Improved accuracy of data and real-time access to all relevant information for controlling the production process, through an easy-to-access and shareable platform.
• Significant reduction in paper usage and ease of access to documentation through digitization of documents and procedures.
• Reliable and complete monitoring of production progress at each station across different lines with clear feedback for operators.
• Monitoring of maintenance to effectively manage downtime and assess its economic impact.