General details
EDIHs involved
Customer
Customer size: Medium (50-249)
Customer turnover: 6 968 462 € (2023)
Challenges
Baltec CNC Technologies is an innovative company producing precision mechanical components for the automotive, multi-purpose machinery, medical rehabilitation and energy industries. The company's main processes are milling and turning on modern CNC machines.
The main challenge: to increase the international competitiveness, expand the network to get new clients and partners for international collaboration. To meet the growing needs of its clients, the company is faced with a shortage of human resources and skills’ gaps. Insufficient staff and lack of skills made it impossible to organise a continuous 24/7 production process.
With the help of consultants from the EDIH4IAE.LT consortium with collaboration of Enterprise Europe Network (EEN Lithuania) and European Cluster Collaboration Platform (ECCP) the aims were to expand the network, get new partners, as well as, develop and implement a digital solution in the company's operations that would enable an efficient use of the facilities with the skills of the available staff, ensuring a continuous 24/7 production process.
Solutions
An advanced robotic manipulator system for CNC machining centres has been installed in the company, together with a customised production work centre monitoring and performance evaluation system based on IIoT technology. These solutions have enabled a more efficient use of equipment and a 24/7 production process. Digitalisation has increased the number of machines to be supervised per worker, as the robotic workstation can autonomously load the machine according to the prepared workpieces and produce products without any intervention of a worker, as well as removing them from the machine.
An integration of the robotic manipulator system in the company's single and series (small-volume) production has enabled full automation of the machining process cycle.
Company's system for monitoring and evaluating the results of customised production work centres has enabled real-time visibility of order execution, tracing product information throughout the process back to the source data. The system reads and stores information on technological production parameters from different technological devices manufactured by different work stations and manufacturers and released in different periods, with or without different types of controllers. The system incorporates special digital filters capable of collecting, storing, analysing and comparing the parameters of the production process, which allow the prediction and evaluation of the efficiency of the production process, including the status of the production equipment itself, by means of special algorithms. The monitoring system also monitors the vibration of the plant, which helps to identify deviations in the performance of the plant. The latter system enables the prevention of breakdowns, the timely scheduling of maintenance work, the reduction of downtime and the improvement of production efficiency, and the real-time monitoring, evaluation and decision-making from the start of the product order to its delivery to the client.
Results and Benefits
In collaboration with EEN partners through both the EDIH and EEN networks, BCT participated in approximately 3 B2B events, 2 business missions, 3 international exhibitions per year. BCT successfully applied for and secured funding for the "NoBoCap" project and EENergy grant, several memberships in the international clusters achieved. Through these networks, and with outreach from international cluster partners, BCT, in cooperation with ECCP, achieved several memberships in international clusters. Additionally, the "InoConnect" project funding was secured.
The digital technological solutions implemented in the company have fundamentally transformed its operations, elevating its competitive level. These solutions enabled the company to double the number of machines under operator supervision from two CNC centers to four, extend machine operating times without direct employee intervention, and ensure a continuous 24/7 production process. As a result, machine productivity increased by 30%.
The installation of a plant monitoring system has prevented unplanned critical equipment downtime, allowed for the scheduling of routine repairs at optimal times, thereby extending equipment life, and halved downtime while reducing unplanned downtime by up to 10%.
Participation in this digital challenge has provided the consultants of the EDIH4IAE.LT consortium with valuable experience, which will be shared with other manufacturing companies pursuing digital transformation.
Perceived social/economic impact
The digital transformation has enabled the company to operate more efficiently:
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to achieve significantly higher production volumes with fewer employees;
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to increase the productivity of the equipment by 30%, to halve the downtime of the equipment;
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to reduce the unscheduled downtime of the equipment by up to 10%;
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to ensure uninterrupted 24/7 production.
Therefore, thanks to the service provided by EDIH4IAE.LT, BCT has ensured the hability to meet the needs of its customers and to strengthen the company's competitive position in the market.
Measurable data
The ability to run the machines 24/7 has been achieved, doubling productivity - where previously an operator could look after two machines at the same time, he now looks after four, assigning them to jobs and making sure everything runs smoothly.
The productivity of the metal cutting machine has increased by 30%, thanks to the automated feeding of the raw material and the removal of the workpiece with the robotic arm. The plant's vibration monitoring system has reduced unplanned downtime by up to 10%.
DMA score and results - Stage 0
In the beginning of working with the company a digital maturity assessment was performed. Below is the results of T0 DMA:
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Digital Business Strategy (23%)
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Digital Readiness (19%)
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Human-Centric Digitalisation (14%)
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Data Governance (7%)
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Automation & AI (40%)
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Green Digitalization (30%)
Lessons learned
International collaboration is crucial for enhancing international competitiveness, particularly through the EEN, ECCP and EDIH networks. These networks play a vital role in expanding the client base and connecting with new partners. Leveraging the combined expertise of the EDIH4IAE.LT consortium, along with the resources and support from the EEN and ECCP networks, allowed the company to effectively address its digital challenges and increase the client base and reach new partners. This collaboration helped the company save resources, make timely decisions, reduce investment risks, and gain a broader perspective—often overlooked when working within the company's own borders.
The EDIH4IAE.LT consortium, supported by the EEN and ECCP networks, has proven that engaging a diverse range of competencies from these networks leads to superior service and more impactful solutions for the client.
The Benefits of the collaboration
In collaboration with EEN partners through both the EDIH and EEN networks, BCT participated in approximately 3 B2B events, 2 business missions, 3 international exhibitions per year. BCT successfully applied for and secured funding for the "NoBoCap" project and EENergy grant, several memberships in the international clusters achieved. Through these networks, and with outreach from international cluster partners, BCT, in cooperation with ECCP, achieved several memberships in international clusters. Additionally, the "InoConnect" project funding was secured.
To extend the client base and reach new partners, collaboration with EEN Lithuania and ECCP networks was leveraged, where following steps were taken:
• Approximately 20 B2B events per year were offered;
• Approximately 20 business missions per year were offered;
• Approximately 15 international exhibitions per year were offered;
• Consultations on funding opportunities including EIT; Manufacturing, BSR, Eurostars, and others;
• Consultation on the EENergy grant;
• Outreaching international clusters for membership.
Going further, the company also solved a high level of human resources need problem - using the knowledge, skills, digital technologies recommended by the EDIH4IAE.LT and suppliers recommended by EEN Lithuania consortium's consultants, an advanced robotic manipulator system for CNC machining centres has been installed in the company, together with a customised production work centre monitoring and performance evaluation system based on Industrial Internet of Things (IIoT) technology.
Lessons learned – do’s and don’ts of the collaboration
International collaboration is crucial for enhancing international competitiveness, particularly through the EEN, ECCP, and EDIH networks. These networks play a vital role in expanding the client base and connecting with new partners. Leveraging the combined expertise of the EDIH4IAE.LT consortium, along with the resources and support from the EEN and ECCP networks, allowed the company to effectively address its digital challenges and increase the client base and reach new partners. This collaboration helped the company save resources, make timely decisions, reduce investment risks, and gain a broader perspective—often overlooked when working within the company's own borders.
The EDIH4IAE.LT consortium, supported by the EEN and ECCP networks, has proven that engaging a diverse range of competencies from these networks leads to superior service and more impactful solutions for the client.
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