Virtual planning for efficient production: How stahlotec is breaking new ground with Halocline

Medium-sized industrial companies such as stahlotec from Hagen a.T.W. are caught between efficiency pressures, rising energy costs and a shortage of skilled workers. As a welding company specializing in metal joining technology, stahlotec is active both nationally and internationally. In order to remain competitive in the future, the company relies on technological innovations - especially in the planning and design of production processes.

Key challenges facing the industry

• Global price and efficiency pressure
• Skills shortage and high training requirements
• Need for reliable planning for complex system layouts
• Claim to minimized downtimes through predictive wear planning
• Scarce land resources that must be used efficiently
• Difficulty communicating and coordinating changes to production planning internally

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Solution approach

To meet these challenges decisively and turn them into an advantage, stahlotec also uses Halocline's production planning software for the virtual planning of its production environments.

The focus is on three central applications:

• Planning security for new orders and machines
  3D planning of production areas allows stahlotec to check in advance how much space machines, material storage and work areas actually need. This enables a realistic assessment of space requirements, avoids bottlenecks and ensures reliable, error-free processes when scheduling new orders.
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• Optimized workplace design in the planning process
  With virtual production planning in 3D, stahlotec can design working environments and movement areas in such a way that they are ergonomically sensible, clear and efficient. Potentially monotonous or confusing processes are identified and adapted at the planning stage - leading to higher process quality, lower costs and a noticeable reduction in the workload for employees.
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• Early involvement of employees
  Involving employees even before the process begins promotes motivation, acceptance and commitment. Thanks to the bottom-up approach, employees feel that they are taken seriously and actively contribute to the process design. Their practical experience flows directly into the planning, which noticeably increases the quality and feasibility of the new processes.

“Not only do you need innovative ideas - you also need the right tools for effective implementation.”
– Christian Neyer, Managing Director stahlotec

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Key successes

By using Halocline, stahlotec was able to achieve tangible improvements in day-to-day planning - with positive effects on efficiency, communication and innovative strength.

• More planning security
  Precise assessment of space and resource requirements
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• Fewer misunderstandings thanks to visual planning
  3D models enable clear, intuitive communication of layouts and processes. Compared to 2D sketches, there are significantly fewer interpretation errors - everyone involved has a common, realistic understanding. This reduces misunderstandings and queries.
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• Greater agility
  Iterations in planning without physical conversions.
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• Faster onboarding through virtual working environments
  Employees can use visual 3D environments to familiarize themselves with new workstations and processes at an early stage. This shortens the familiarization period, reduces error rates and ensures a faster, more secure arrival in the new work area.

“Even simple 3D models are a great benefit for us in terms of internal communication - everyone involved immediately understands what is meant.”
– Christian Neyer, Managing Director stahlotec

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Partnership & further development

The cooperation between Halocline and stahlotec goes beyond the typical customer assignment: stahlotec is involved as an active development partner and contributes its practical experience directly to product development.

One Result of This Cooperation

"Halocline Free", a free version of the software, especially for smaller companies with limited entry barriers.

“As a result of the discussions and cooperation with stahlotec, we are now providing a free version of our software, Halocline Free.”
– Thomas Schüler, Managing Director Halocline

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Customer focus that makes the difference

At Halocline, service does not end with the product - it really begins there. Our customers benefit from a close, personal exchange, fast response times and support that thinks along with them. This reliability creates trust and noticeably sets us apart in everyday project work.

“Halocline thinks along with you, reacts immediately and delivers - exactly what you want from a real partner.”
– Martin Curth, Authorized representative stahlotec