At the Danfoss plant in Castel San Pietro Terme, Bologna, a compact but globally strategic production facility, digital innovation has also reached personnel management. During the recent Factory Tour organized by Danfoss, we had the opportunity to explore closely how AWMS – Workforce Management System – has significantly transformed human resources planning and production organization.
A complex challenge: 3,000 part numbers and staff to be trained every day
The Italian plant of Danfoss’s OGS (Orbital and Gear Solutions) business unit, with a production of approximately 1,250 hydraulic pumps and motors per day, is confronted daily with a high variety of product codes and a highly specialized cell organization. Each production station requires specific skills, and the physical and operational constraints of the operators must be considered to ensure ergonomics, quality and safety.
From Magnetic Board to Digital Planning
Before the introduction of AWMS, staff planning was based on a physical whiteboard with magnets: a visual but limited system, which entrusted supervisors with the difficult task of remembering the team’s skills, limitations, presence and absences.
AWMS has been a turning point. Thanks to the digital system:
- Supervisors receive automatic suggestions for optimal fit,
- Individual limitations and absences are visible in real time (thanks to the integration with Zucchetti),
- Skills are assigned and certified digitally,
- The system warns you when a skill is expiring or has not been exercised for some time.
“AWMS has allowed us to make the workholding error-proof: supervisors now only make small adjustments to the assignments proposed by the system,” explained Sarah Dal Pra, Lean Manager at the plant.
Rotation, well-being and less conflict
Another positive effect of adopting AWMS was the introduction of systematic rotation of operators. This approach, often difficult to implement with manual tools, has helped improve the internal climate and reduce conflicts. Furthermore, AWMS integrates with corporate wellness initiatives: from the relaxation and wellness areas to the internal gym, everything is designed to enhance the person even in the most operational contexts.
A compact but cutting-edge factory
The Danfoss case shows how even a small-sized company, with about fifty operators and a lean structure, can become a model of innovation. The Italian plant, while maintaining the historical identity of Turolla, has been able to integrate automotive standards, Power BI dashboards, lean management and digital software such as AWMS to remain competitive in a demanding and constantly evolving global market.
AWMS as an enabler of digital transition
Today Danfoss is able to:
- Staff your staff in just a few clicks, with guaranteed compliance with IATF standards,
- Monitor the effectiveness of skills in real time,
- Respond quickly to unexpected events such as breakdowns or unexpected absences.
Danfoss’ experience confirms that digitalization does not only involve machinery or production flows, but also – and above all – the intelligent management of people. And AWMS confirms itself as a key tool to enable this transition.
