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moldmakingtechnology.com 45 the most advanced and sophisticated tool and moldmak- ing shops in Germany. Digital touchscreens in the factory ensure all processes are transparent and visible for everyone in real time. All machines and departments are networked via a manufacturing execution system (MES) and a systems, applications and products (SAP) system. MES is a control system for managing and monitoring work in process, and a SAP system deals with data security and integrity. Phoenix runs a first-in-first-out concept, managing to reduce lead times by as much as 50 percent. However, before digitiz- ing its whole shop, and before automation systems or an optimized product flow system were installed and realized, Phoenix looked at each single manufacturing step and ana- lyzed and optimized all processes before networking the machines via MES and SAP and digitizing the system. The result is fast turnaround times for its customers, even for complex tools. What do you mean by complex tools? Seul: There is currently a trend towards product diversifica- tion and increasing complexity, whether in the large electri- cal, appliance, telecommunications, automotive or medical industries. Take the Audi radiator grill, for example. There CONTRIBUTOR Barbara Schulz is Gardner Business Media's European correspondent. She can be reached at bschulz@gardnerweb.com. are 14 different versions for the A4 model alone, and all have to be injection-molded with two molds, as 14 different molds would not be efficient enough, of course. These tools then have to be flexible enough to change from one version to another during the injection molding process, from shot to shot, depending on the order. How do highly skilled people factor into understanding customer demands and meeting their requirements? Seul: Toolmakers are an essential part of a shop's core competencies, which is what you can't buy. You can buy machines, you can automate and optimize your processes as described earlier, you can acquire other companies to expand capabilities, and so forth. But you cannot buy people. Phoenix Contact's tool shop wouldn't be where it is today without its head, Ralf Gärtner, who is enthusiastic, clever and, most of all, 100-percent dedicated to what he does. That's the key above all. If machines were to decide...