Some Projects

About the Customer

Vale is a Brazilian multinational diversified Metals & Mining corporation and one of the largest logistics operators in Brazil. In addition to being the third largest mining company in the world, the customer is also the largest producer of iron ore, pellets, and the second largest producer of nickel. In the electric energy sector, the corporation participates in consortia and currently operates nine hydroelectric plants.

The Customer’s Need

Initially, the Hyla Soft team came to work with Vale as high-level product consultants on a large project to implement Siemens SIMATIC IT for MES across their production enterprise. New to the product, the customer turned to Siemens for support. Siemens partnered with Hyla Soft for the initiative, recognizing us as the solution partner with the strongest expertise and experience working with SIMATIC IT. The combined team was able to deliver both the product knowledge and industry know-how that the customer was seeking.

About the Project

Hyla Soft consultants completed a comprehensive quality assessment, identified (many) points for improvement, and designed and provided the guidelines to improve the MES solution in order to fulfill Vale's specific needs. In addition, our presence in Brazil allowed us to provide continuous local support to the customer.

Eventually, Hyla Soft’s expertise and project management capabilities led us to take on full governance of the company’s MES solution. We supported and executed a successful pilot MES rollout in the first of the corporation’s 50 Brazilian plants. A successful pilot led to deployment in 2 more plants shortly after. Our consultants provided full solution oversight and governance for the customer for many years, building a strong relationship with the customer's IT team and management that remains to today.

Hyla Soft’s Consulting Advantage

As is often the case, the benefits Hyla Soft provided to Vale were not a direct result of the product in scope alone. The real value we bring to our customers is our IT product and manufacturing industry expertise. Thanks to our depth of knowledge of the Siemens SIMATIC IT Suite as well as years of experience implementing it in the Mining & Metals sector, the customer chose us as the right system integrator for their MES implementation.

Hyla Soft and Siemens consultants worked together and were able to take their expertise and share it with the customer’s team, helping them prepare the solution and ultimately reach the point at which the system was ready to go live successfully. The services provided to the customer by Hyla Soft during this project include:

  • Quality Assessment
  • Process Improvement
  • Solution Governance
  • High-Level Consulting
  • Technical Product Expertise
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About The Customer

The customer is one of the world’s largest oilfield services companies. The company operates in over 90 countries, providing the Oil & Gas industry with products and services for drilling, formation evaluation, completion, production, and reservoir consulting. The customer has its headquarters in the American General Center in Neartown, Houston.

The Customer's Need

The customer produces many of the tools used for oilfield commissioning and extraction, such as drilling, evaluation, and safety equipment. With a wide variety of component families to produce, CNC machining is an essential piece of their manufacturing capabilities.

When Hyla Soft started working with the customer, they were already using Siemens Teamcenter to manage product design data in their PLM system. However, the customer wanted to improve the way in which they managed their manufacturing data, including CAM files and NC programs, which lacked a centralized location. The customer’s engineers often found themselves losing too much time and effort trying to manage existing programs, as well as transferring new programs and program revisions to the machines.

As a result, the customer decided to start managing their CAM data – including set up sheets, cutting simulation movies, and NC programs – in Teamcenter, and also implementing Shop Floor Connect, the Siemens DNC solution, to transfer NC data directly from Teamcenter to their CNC machines.

About The Project

After being chosen by the customer to lead the rollout of a DNC system at their flagship manufacturing center, Hyla Soft acted as the system integrator, delivering all phases of the project. In collaboration with the customer’s engineering and manufacturing teams, our consultants helped define the new standards for managing NC programs with revision control and release statuses. These new standards were designed to meet the requirements of all project stakeholders, including corporate, PLM, and manufacturing groups.

Hyla Soft consultants then configured the new DNC system according to the developed solution specifications. After validating the solution, Hyla Soft connected each CNC machine on the shop floor to the new DNC system now deployed on their production environment.

At each stage of the process, Hyla Soft involved the customer’s personnel who would be responsible for supporting the system after go-live. The support personnel accompanied Hyla Soft consultants in connecting CNC machines to the system, preparing them to take ownership of their new DNC network.

The result for the customer was a more streamlined and standardized process for manufacturing data management. Instead of “tribal knowledge,” NC programs are now fully organized and revision controlled. With effective DNC, machining has also become a much stronger capability for the customer.

Hyla Soft's Advantage

In the end, Hyla Soft was the right choice to lead the customer in this project. The customer chose Hyla Soft for many reasons, amongst them our established CNC Machining & DNC Solutions practice comprised of a world class team of experts and consultants, our long-standing experience working within the Oil & Gas industry, as well as our company’s niche and proven approach to leverage the Siemens Teamcenter PLM offering for both design data and manufacturing data management in order to drive and maximize business process improvement for our customers.

We are proud to have delivered a successful project implementation that not only fulfilled all of the customer's needs and requirements, but ultimately helped the customer achieve both their production and business goals. We look forward to more collaboration and initiatives with the company in the future.

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About The Customer

Magneti Marelli is an international group and leader in the design and production of high-technology components for the automotive industry. With more than 38,000 employees, 89 production plants, 12 R&D centers and 26 application centers, the group is currently present in 19 countries and is a major supplier for some of the best-known car manufacturers in Europe, North and South America, and Asia. With a combined annual turnover exceeding 6 billion euros, the company’s 3 main business lines include a Lighting Division, a Powertrain Control System Division, and an Electronics Division.

The Customer's Need

Initially, Hyla Soft started working with Magneti Marelli's Electronics Division through our long-standing partnership with Siemens. The solution in scope was a Manufacturing Execution System (MES) based on Siemens' SIMATIC IT Production Suite and Mechatronics Assembly Line (MAL) Library.

The particular production needs of the customer, combined with the specific demands of their clients, presented many challenges for the customer in terms of production. In accordance with the customer’s requests, the MES solution proposed was designed to:

  • Ensure that the correct production cycle was continuously followed in order to reduce repairs, scraps, and component waste
  • Track production operations on every produced item, along with additional information, such as properties, measures, and components used
  • Ensure MES control between the Enterprise Resource Planning (ERP) system and the production lines

Following the deployment of SIMATIC IT for MES in all 3 of the customer’s European electronics plants, the customer started looking for a system integrator to support and help maintain the MES solution as well as to ensure that the new system would satisfy all of their requirements. As the Siemens solution partner with one of the strongest backgrounds working with SIMATIC IT for MES, Hyla Soft was chosen by the customer as their system integrator for this initiative.

About The Project

Hyla Soft consultants’ initial work for Magneti Marelli involved providing full Maintenance & Support for the customer’s existing MES solution in all 3 plants. As part of the solution governance agreement, our consultants are available and provide local support to the customer 24 hours a day, 7 days a week.

In addition, Hyla Soft consultants configure the SIMATIC IT product so that it continuously provides all of the core functionalities necessary to both satisfy the customer's specific production requirements and better respond to their own customers’ needs at the same time:

  • Process Interlocking – The system provides the ability to check on a range of standard and customized conditions in order to determine whether a process step should take place or not. It is up to the shop floor devices to send an interlocking request to SIMATIC IT and to conform to the response obtained.
  • Product Traceability – The system provides the ability to track any operation performed on produced items and property, to measure values, as communicated by shop floor devices, and to trace its genealogy in terms of components used during production.
  • Quality Management  The system provides the ability to track defects and quality issues found during analysis and/or test operations, as communicated by shop floor devices or operator screens. The system provides functionalities to assist the quality operator during repairs and to track the closure of open defects. 
  • Connection to Shop Floor Devices  Connectivity with shop floor devices is performed via text file exchange. Connectivity with standard or custom user screens developed by Siemens is performed with a combination of text file exchange and synchronous direct communication with SIMATIC IT MAL.

Hyla Soft's Advantage

In the next couple of years, our scope of work for Magneti Marelli will expand beyond just solution maintenance. With the support of Hyla Soft, the customer has decided to extend the MES solution to encompass all of the production lines in all 3 electronics plants. There is also an exciting new opportunity for Hyla Soft in the customer’s plant, which is exclusively dedicated to the production of electronics devices commissioned by some of their world-class automotive clients, including FIAT, Jeep, and BMW. Per the request of these big-name clients, the customer will be building additional production lines in the plant solely limited to the production of specific components for each automaker. Following their addition, Hyla Soft will be responsible for extending and implementing the MES solution to all newly-built production lines.

As always, however, our goal extends far beyond just this initiative. Hyla Soft aims to expand our work for the customer, grow the partnership, and create a long-term relationship. We foresee supporting new and different initiatives for the customer in the future, ranging from Supply Chain Management (SCM) to Production Scheduling to IT Training and beyond, and ultimately working with not only one but all three of the customer’s manufacturing divisions. Our company’s unique ability to offer end-to-end technology solutions to our clients makes us much more valuable than any other system integrator or consulting company in the world. Our ability to offer analysis, consulting, implementation as well as maintenance & support expertise and services from the shop floor to executive management levels and across all of our clients' manufacturing processes is the reason behind our success in helping our customers gain a competitive edge in their industry.

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About the Customer

Baxter International is a leading American healthcare company that manufactures products to treat hemophilia, kidney disease, immune disorders, and other chronic and acute medical conditions. With an annual revenue that exceeds $15 billion, the company is a leader in both the bioscience and medical product industries.

The Customer's Need

Hyla Soft started working with the U.S. branch of Baxter during the company’s initiative to implement an enterprise-level Electronic Batch Records (EBR) and Manufacturing Execution System (MES) solution across their entire production division. The customer’s new EBR/MES system was based on SIMATIC IT XFP, a Siemens MES platform designed specifically for Life Science Manufacturing in order to improve efficiency, quality, and visibility within the challenging industry’s production processes.

After a successful MES implementation in Europe, the customer decided to extend the new system to cover multiple product lines at several new greenfield and existing facilities in the United States. The scope of the system covered the customer’s entire manufacturing process, providing full EBR, weighing and dispensing management, materials management, equipment management, sample management, and full integration with several external systems such as ERP, LIMS, DMS, etc.

As Siemens’ preferred integration partner and thanks to our leading MES practice with the top functional experts on SIMATIC IT XFP, not to mention our capability to provide the best resources and local support on a global scale, Hyla Soft was chosen as the official system integrator for the customer's North American initiative.

About The Project

Services provided to Baxter by the Hyla Soft team during the multi-site, multi-year program include:

  • Technical Leadership
  • System Architecture Design
  • EBR Design & Development
  • System Integration Design & Development
  • Business Case Analysis (ROI)
  • Design Documentation Preparation
  • 100% On-Site Consulting Presence
  • Remote Development & Support

Per the commitment we make to all of our customers, the Hyla Soft consulting and management teams built a strong and open relationship with the customer in order to ensure that our work and solution fulfilled all of the company’s needs and expectations from day 1 until the completion of the project. Hyla Soft provided a combination of on-site technical experts, remote development teams, and just-in-time technical and functional support to partner with and augment the client’s existing staff and to help ensure the success of the EBR/MES rollout.

By leveraging our diverse pool of talented consultants, Hyla Soft was able to provide both the technical resources and leadership required to successfully implement and deploy the customer's new MES solution.

Hyla Soft's Advantage

Both our partnership and scope of work with Baxter continues to grow and strengthen. In addition to the many business benefits the customer has gained from the new EBR/MES system now live at their production sites, Hyla Soft’s consulting offering played a key role in the success of this initiative.

We were able to deliver superior product knowledge and experience as well as the best resources available in the industry today. Hyla Soft provided the services necessary to help the customer realize the product’s potential for their specific production and business requirements. In short, Hyla Soft partnered with the client to provide the right resources with the right expertise in the right locations at the right time.

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About The Customer

The customer is a leading U.S. developer and manufacturer of compressed air solutions. A pioneer in air compressor technology, the company offers a complete line of compressed air system products including portable and stationary compressors and accompanying aftermarket equipment. With manufacturing facilities on three continents and a worldwide distribution network, the customer has established itself as a global leader in the industry.

The Customer's Need

Hyla Soft completed the analysis phase of a comprehensive Siemens Teamcenter Manufacturing implementation for the customer. In our first engagement with the customer, a manufacturer of Heavy Machinery, Hyla Soft consultants designed and developed a complete solution to help the customer realize the following business benefits:

  • Reduce scrap and rework by linking manufacturing data to engineering data for superior change control capabilities.
  • Speed up new product development time with digital process planning and validation.
  • Reduce inventory and material handling costs by promoting accuracy of parts assignment to manufacturing work centers.
  • Increase quality and decrease assembly issues and rework by delivering digital Work Instructions paperless-ly to shop floor personnel.
  • Increase global manufacturing capabilities and flexibility by sharing manufacturing process plans and data with other facilities.

Ultimately, the aim of the solution is to unite both the customer’s manufacturing data and their engineering data into the same system, as a result driving improvements within not only their manufacturing engineering group, but across their design engineering, quality, operations, service, supply chain, and inventory groups as well, not to mention on the shop floor itself.

About The Project

Hyla Soft’s approach to requirements gathering is to get our customer hands-on with the software from day 1. Throughout our analysis for the customer, Hyla Soft and the customer’s end users worked directly with the Teamcenter Manufacturing products in order to gather business requirements, user requirements, and functional requirements of the final solution. This approach enhanced the requirements gathering process by allowing project stakeholders to understand the future system in the context of their business and manufacturing processes.

The result of our analysis for the customer was a complete system design for the customer, which will include:

  • Teamcenter Manufacturing Process Planner to create Bill of Process (BOP), with digital BOP validation, and process Work Instructions attached directly to the BOP.
  • Cortona3D’s Integration to Teamcenter to create 3D animations of the assembly process, attached directly to the BOP.
  • Teamcenter Electronic Work Instructions to deliver digital Work Instructions directly from the Teamcenter BOP to the shop floor.

The new system design also encompasses the CNC machining division, which will receive cutting-edge parts manufacturing solutions from Siemens, including NX-CAM and Shop Floor Connect for Teamcenter.

Hyla Soft's Advantage

Proud to have one of the most extensive backgrounds working with the Siemens IT offering, Hyla Soft is the only company in the world partnered with 3 of the software giant’s divisions. Product Lifecycle Management (PLM) is undoubtedly one of our strongest areas of experience and expertise. While most companies see Teamcenter as a tool to manage engineering data alone, Hyla Soft focuses on Teamcenter to bridge the gap between engineering and production as it relates to manufacturing.

Thanks to our continuous investment in expanding how we leverage the Siemens Teamcenter offering for our customers and the manufacturing industry, our consultants’ unmatched knowledge of and experience working with the product firsthand, and our practice’s end-to-end expertise and capabilities, the result of this initiative for the customer will be a complete solution for unparalleled manufacturing data management, from top floor to shop floor.

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About The Customer

Hyla Soft’s Training Division is working with Coca Cola Corporation, one of the largest bottled beverage companies in the world. With an annual revenue exceeding $45 billion, the customer is an international powerhouse in the manufacturing, retail and marketing of nonalcoholic beverage concentrates and syrups.

The Customer's Need

Hyla Soft has closed a successful year-long project working with Coca Cola, delivering the software training and go-live system support necessary for the customer’s Statistical Process Control (SPC) and Quality Control hardware and software solution deployment. The scope of the enterprise IT rollout included all 79 of the customer’s U.S. production plants. As a result, the customer needed a system integrator with not only technical and product expertise, but an in-depth understanding of the Food & Beverage manufacturing environment and the capability to provide the best IT training and experienced resources as well. Thanks to our industry footprint and proven, pro-active training methodology, the customer chose Hyla Soft as the right partner to lead the  company (and its workforce) to a successful launch of the new quality control system.

About The Project

The ongoing implementation of the new system, coupled with the training and support provided by Hyla Soft consultants, has already proved to be beneficial for Coca Cola. The deployment has helped production sites where the system is live:

  • Improve production process control
  • Reduce re-work and increase live data collection to reduce recall potential
  • Decrease environmental impact by removing the need for paperwork

Hyla Soft’s real value added to the customer’s IT initiative, however, stems from our dynamic, hands-on, one-on-one training approach. Hyla Soft consultants work with management at each bottling facility to develop a site-specific training plan and schedule in order to ensure 100% training coverage. Each production operator identified in the site plan is then trained individually based on his or her specific role. Training is completed in a hands-on environment in order to help the operators better understand the new system requirements, as well as to help them retain all the information they need to successfully transition to the software platform. With the support of site-specific work aids as well as with the added capability to provide training in both English and Spanish, Hyla Soft consultants make the transition easier and more effective for both the plant’s operators and managers. More importantly, by replicating this training approach at each manufacturing site, Hyla Soft helps ensure a standard training solution that is identical across the entire scope of the rollout.

Hyla Soft's Advantage

With all previous responsibilities intact, Hyla Soft has expanded our scope of work for Coca Cola moving forward, branching out to integrate newer and more pieces of equipment and software from each plant, extending the initiative to include different customer manufacturing sites outside of the United States, and providing both local and remote support for the new system. Regardless of where this project may take us in the future, the unmatched level of education, diversity, experience, and skills that our consultants can offer the customer ensures our ability to jump into any arena the customer may require of us without hesitation and with confidence that we can deliver. As our consultants continue to expand their expertise for this customer, our team expects this initiative to become an ongoing program and lasting partnership for years to come.

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About The Customer

Hyla Soft is working with Zimmer, a worldwide leader in musculoskeletal healthcare. The company is specialized in the design, development, manufacturing, and marketing of orthopaedic and muscoskeletal healthcare products, such as knee and hip replacements. The customer has operations in more than 25 countries around the world and sells products in more than 100 countries.

Industry Challenges

In the field of medical manufacturing, software innovation encounters uniquely challenging obstacles. Not the least of these are regulatory compliance requirements. Each step of a solution rollout must be rigorously planned, carefully executed, and painstakingly validated. Given the effort required to implement even a single suite of enterprise software in this environment, it is no wonder that the industry has been slower to pursue multi-tiered integration initiatives. Such projects require a mindful analysis of interoperability options between a diverse array of hardware and software as well as an experienced eye to identify potential gaps and redundancies as data flows between systems. For these reasons, it is critical that medical manufacturing enterprises carefully choose an integration partner with the particular skills hnkand experience required for a successful and cost-effective rollout.

The Customer's Need

Zimmer is also subjected to these industry challenges, which include strict government regulations and requirements for top quality products. To meet these demands, the customer needed a software solution to help monitor and control their manufacturing processes. Statistical Process Control, commonly known as SPC, is an industry standard methodology for measuring and controlling quality during the manufacturing process. Our partner and a leader in quality software solutions provides a tool for manufacturers to implement SPC. One of the customer's sites had implemented this SPC solution; the company needed support moving forward to roll this out across all of their sites globally. The customer turned to Hyla Soft to help with these needs.

About The Project

The initial phase of our consultants’ work involved an in-depth analysis of Zimmer's existing production environment and processes in order to gain a comprehensive understanding of their specific needs and requirements. Based on this analysis, Hyla Soft worked with the customer’s IT team to define the solution design standards for a global implementation of the SPC solution.

Hyla Soft consultants also support the go-live and validation of the system at each of the customer’s production sites. During each deployment, a team of trainers from Hyla Soft is onsite in order to provide hands-on demonstrations and guidance to ensure that the customer’s operators have a smooth transition to the new environment. At the same time, our software validation team ensures compliance with the rigorous government standards for the industry.

Hyla Soft's Advantage

Hyla Soft is proud to have been selected as the partner for such an integration at one of the world’s leading medical device manufacturers. Our consultants are confidently leading a global effort to standardize the entire corporation on the new platform. By the completion of this project, the customer will have a validated SPC system implemented globally to ensure the highest degree of quality for their healthcare products. Through our industry experience and professionalism, Hyla Soft is excited to contribute toward an initiative that will add enormous value to our Zimmer's manufacturing enterprise for years to come.

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