DIGITAL
TRANSFORMATION
AT TRISTAR STEEL
WITH KFACTORY®
Case study
Context:
The collection of production data
at Tristar was done manually,
using worksheets and disparate
computer systems. This was prone
to errors, delays and gave an in-
complete picture of production
processes. As a result, the compa-
ny faced the following challenges:
■ Lack of visibility: No overall
visibility on the real-time per-
formance of production lines.
■ Incorrect data: Manual errors
were affecting the accuracy of
reports and analysis.
■ Delays in reporting: Reports
were generated late, making
it difficult to take operational
decisions.
■ Difficulties
in
optimizing
processes: Lack of accurate
and up-to-date data prevents
problems from being quickly
identified and remedied.
■ The operational processes of
quality, stock management
and production order man-
agement were hampered by
the lack of real-time data.
DIGITAL TRANSFORMATION
AT TRISTAR STEEL WITH
KFACTORY®
The Solution:
To overcome these challenges,
Tristar Steel decided to imple-
ment the KFactory® platform. The
solution was implemented on a
complex production line, integrat-
ing various industrial machines.
The
KFactory®
team
worked
closely with the company’s opera-
tional team to ensure a successful
implementation.
“The main reasons for choosing
the KFactory® solution are:
■ The need to monitor perfor-
mance in real time and iden-
tify bottlenecks so that we
can make quick and informed
decisions;
■ The need to improve produc-
tivity and reduce downtime;
■ The need for improved trace-
ability of both materials and
labor;
■ The
need
of
improv-
ing
individual
and
group
responsibilities;
■ The need for real-time data
collection and analysis to op-
timize processes and reduce
costs;
■ Flexibility and scalability;
■ Improving the efficiency,
quality and competitiveness
of production operations, ul-
timately contributing to high-
er profitability and increased
customer portfolio.
Tristar Steel, part of the Akçelik Group, a globally renowned innovative company speciali-
sing in the production of hard chrome steel bars and linear shafts, has opted for the digita-
lisation of its production processes by implementing the KFactory® platform. Prior to this
initiative, the company faced significant challenges in collecting and analysing production
data, which directly affected operational efficiency and decision-making.
2 I KFactory®
20%
PRODUCTION EFFICIENCY
registered growth in
the first 3 months of
implementation
50
USERS
all operators use the
platform
In conclusion I define working
with the KFactory® Team as fol-
lows: Effectiveness + Efficiency =
Excellence.
We chose KFactory® because
this solution perfectly fits our
specific needs and will help us
achieve our growth and develop-
ment objectives.
for the management team (mid-
dle and top level) to help optimize
scheduling and workflow, reduce
delivery times and improve on-
time delivery performance.
KFactory® gives operators and
managers easy access to informa-
tion and tools, allowing them to
take control of their work process-
es and contribute to continuous
improvement. It promotes better
communication and collaboration
between different departments,
teams and locations, leading to
a cohesive production process.”,
Nicoleta Dobre, CEO Tristar Steel
Tristar Steel continues to exploit
the potential of the KFactory®
platform. The next project mile-
stones include:
■ Monitor energy consumption
to reduce costs and improve
sustainability.
■ Carbon footprint calculation
to comply with environmental
regulations and demonstrate
the company’s commitment to
sustainability.
That implementation was the
fastest and most efficient imple-
mentation to date. The collabo-
ration with the KFactory® team
has been one that has exceeded
expectations with its profession-
alism and efficiency.”, Nicoleta
Dobre, CEO Tristar Steel.
Features of the chosen
solution, best practices:
■ Automated data collection:
production data is collected
automatically and in real
time, eliminating human er-
ror and improving the accura-
cy of information.
■ Real-time visibility: the plat-
form provides a clear and up-
to-date picture of equipment
and operator performance.
■ Advanced
analytics:
KFactory® Analytics enables
customized reporting and data
analysis to identify trends,
anomalies and opportunities
for improvement.
■ Integration with ERP system:
the platform integrates with
the Navision ERP system to
take production orders and
automatically transmit the
collected data.
Results:
The implementation of KFactory®
has had a significant impact on
Tristar Steel’s operations:
■ In the first 3 months of im-
plementation there was a
20% increase in production
efficiency.
■ Now the rules and execution
times for orders can be set
correctly.
■ Real-time visibility on order
execution status.
■ Improved data quality: the
data collected is more accu-
rate and reliable, allowing
more accurate performance
analysis.
“As a result, in the first 3 months
after implementation we have
seen a 20% increase in production
efficiency; all operators (50 peo-
ple) are using the KFactory® plat-
form, all equipment in the pro-
duction flow is monitored with it.
The solution is also the daily tool
KFactory® I 3
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