In times of global uncertainty and rapidly changing conditions, a company's resilience is becoming increasingly important. Especially in the electroplating industry, which is characterized by strict regulations and technological innovations, it is becoming a decisive success factor. The ability not only to adapt but also to emerge stronger from crises is the key to long-term competitiveness and sustainability today. This article uses examples to show how B+T Oberflächentechnik GmbH is securing its stability and preparing for future challenges through strategic resilience measures in the areas of energy, chemicals, spare parts and personnel.
Resilience and the framework conditions
"Resilience" has its origins in the Latin "resilire" and can be translated as "bounce back, rebound". The term is on everyone's lips today and is used to describe the ability of people or systems to withstand external influences and adapt to changing conditions.
At B+T, the review of actual and potential disruptive factors is a continuous, regular process in order to take timely and forward-looking measures. The aim is to achieve a new state of equilibrium, as a return to the initial state is not possible or not desired.
What influencing factors are we talking about? Resilience in relation to political framework conditions
Stricter legal requirements, such as lower chemical limits or EU climate targets (climate-neutral by 2050), are putting electroplating companies under increasing pressure. In addition, geopolitical crises such as wars and pandemics are influencing supply chains and production processes through economic embargoes and lockdowns.
Resilience in relation to economic conditions
Economic resilience requires adaptation to volatile markets and uncertain supply chains. Companies must secure their supply of raw materials and energy availability while keeping an eye on growing customer requirements. Flexibility and forward-looking planning are essential in order to remain competitive in the long term despite fluctuating costs and unpredictable market changes.
Resilience in relation to social framework conditions
The shortage of skilled workers and demographic change pose major challenges. Companies must adapt to changing education systems, a shift in values towards a work-life balance and the integration of immigrants (Fig. 1).
Fig. 1: Companies are subject to external influencing factors. (Symbols from PowerPoint)
It is important to react flexibly to these changes and to ensure resilience through sustainable measures; these include alternative procurement strategies, diversification of materials or suppliers, reducing consumption or stockpiling, as well as making your own company an attractive workplace.
Resilience in the Industry 4.0 concept - the guiding model at B+T
The integration of Industry 4.0 principles is a central component of modern resilience strategies. B+T is guided by the model of the Federal Ministry of Economics (BMWK). The strategic fields of action of sovereignty, interoperability and sustainability provide B+T with tangible points of reference for review and correction in the adaptation process. The aim of the company's management is to act freely and independently in the long term within the given framework conditions. All of this takes place in a lively exchange with suppliers, customers, authorities, market companions and other interest groups. Involvement in various associations, participation in many research projects and maintaining contacts, e.g. with educational institutions, are matters close to B+T's heart and offer the opportunity to keep a finger on the pulse at all times. Decisions are made with a view to their sustainability in order to survive on the market in the long term. In addition to climate protection, this also includes good working conditions, training opportunities and, of course, social acceptance (Fig. 2).
A central element of Industry 4.0 is the digitalization of production processes and the use of artificial intelligence (AI), which ensure increased automation and efficiency. They help to better anticipate bottlenecks and implement alternative solutions more quickly. B+T sees itself as a pioneer in the industry in this area. The company is currently in the process of introducing AI into the complex process of preparing quotations. Investments in such innovations are a high priority at B+T.
Fig. 2: Resilience in the "Industry 4.0" concept. Source: Whitepaper Federal Ministry for Economic Affairs and Climate Protection (BMWK)
Resilience in energy, chemicals, spare parts and human energy
Electroplating companies are extremely energy-intensive. They are also dependent on a constant energy supply as they produce in three shifts, seven days a week. The German government's recent proposal to adapt production to the availability of renewable energies is therefore more than unrealistic.
Due to electricity contracts that are concluded at lower prices over a longer period of time, manufacturing companies are dependent on their supplier, which is why the only remaining measures in this area are savings or the use of new technical options. Equipping systems with sensors, including in the periphery, enables B+T to monitor energy effectively and provides insights for optimizing consumption. Combined with predictive order planning, cost-intensive power peaks can therefore be avoided. Other automation tools, such as the use of RFID technology, help to increase efficiency. AI is now also finding its way into production - B+T was able to gain initial experience with this a few years ago as an application partner in the SmArtPlaS research project.
Chemicals
In order to avoid supply bottlenecks for chemicals - which recently occurred due to the war in Ukraine - and thus the threat of plant downtime, B+T has expanded its sources of supply, optimized its inventories and is focusing on reducing the use of chemicals. The bath chemicals are tested daily by the in-house laboratory, the electrolytes are permanently monitored using online analysis methods and optimized according to the specially developed ProStab/ProOp principle. B+T is demonstrating its expertise in this area in the KI-InGaTec research project. RFID technology is not only used in the storage of chemicals, but also in the production of systems with exchangeable baths (Fig. 3).
Fig. 3: Bath management according to the ProStab/ProOp principle (Photos and graphics: B+T Oberflächentechnik GmbH)
Spare parts
Stock levels of spare parts can be monitored quickly and easily with RFID, and critical parts are ordered in good time or alternatives are sought. Both materials and suppliers are regularly put to the test. For some spare parts, B+T has been able to become more efficient through standardization: the same pumps, valves and similar wear parts are used on the different systems wherever possible. Predictive maintenance helps to extend the service life of machines and prevent breakdowns.
People
People remain the most important element of a successful company, especially in times of skills shortages and demographic change. B+T is a traditional family business, now in its third generation, which attaches great importance to maintaining a family corporate culture. Frank Benner, managing partner of the group of companies, knows all his employees by name and is familiar with their careers and histories. His daughters Annalina and Sarah Benner have been helping out in the company since their school days. In their role as shareholders, they are familiar with all processes and developments in the company (Fig. 4).
At B+T, the focus is on people and their individual skills and strengths are encouraged. Commitment is recognized and rewarded. Electroplating is still an industry dominated by men. At B+T, too, the proportion of women (23%) lags far behind that of their male colleagues. However, women are more strongly represented in top management and in the shareholder structure.
81 employees of the 111-strong workforce in 2023 were German, the others came from Southern and Eastern Europe, Asia or Africa. Their integration into our society is most successful when they are involved in the processes and interact with their colleagues on a day-to-day basis. At B+T, language barriers are overcome using modern technology such as mobile translation devices, pictorial representations or instructions in video format.
Occupational safety is a top priority at B+T. Training and occupational safety information is therefore provided in the relevant language. Employee development is monitored as part of the management review; the training rate for 2023 was 85%, far exceeding the set minimum training rate of 75%.
The operational occupational safety index (ASI) is calculated quarterly using the Failure Mode and Effects Analysis (FMEA) method. All departments are checked against certain criteria. These include, for example, mechanical, electrical, biological or thermal hazards, hazardous substances, fire hazards, physical effects, physical and psychological hazards and hazards due to environmental conditions. This enables B+T to take targeted measures to ensure the safety and health of employees and to minimize accidents at work or damage to health.
The age structure at B+T is rather untypical for Germany as a whole. While the proportion of 40- to 59-year-olds is highest in society as a whole, B+T has the highest proportion of 25- to 39-year-olds. B+T appears to have succeeded in being perceived as an attractive employer.
In 2023, B+T again qualified an above-average number of young people for working life with nine apprentices. The apprenticeships not only cover the typical electroplating professions, but also the entire spectrum of skills required in the company.
B+T is committed to thinking outside the box. The company demonstrates this with its involvement in various research projects and its cooperation with various schools and universities. In a pilot project with the Schwingbach comprehensive school, for example, secondary school pupils are given a two-week internship followed by a practical day (once a week for the rest of the school semester) to help them start their careers; B+T sponsors hardware and know-how at regional schools (Werner-von Siemens School, THS Wetzlar); CTO Edgar Kaufmann, a graduate chemical engineer (FH), regularly gives lectures at vocational schools, e.g. at the Gewerbliche Schule Schwäbisch Gmünd.
Fig. 4: A family business in its third generation: B+T
Proving sustainability
B+T is not obliged to produce an Environmental, Social and Governance (ESG) Sustainability Report - and yet the company has prepared one for 2023. All progress that is of interest to customers, stakeholders and the general public is published in this report.
In it, the management provides key figures for the previous three years in the areas of environment, social affairs and responsible corporate governance and makes the sustainability strategy transparent. Customers receive a certificate that shows theCO2 footprint of their products in relation to the production step at B+T.
Conclusion
Today, resilience is an indispensable component for the sustainable development and long-term success of companies - especially in the electroplating industry. The ability to adapt flexibly to new challenges is strengthened not only by technological innovations, but also by targeted investments in employees and sustainability. Companies that see resilience as a strategic factor secure long-term competitive advantages and at the same time help to overcome global challenges such as climate change, skills shortages and supply chain problems.
However, an important aspect of resilience is also the ability to recognize and seize new opportunities. Recent political developments - from stricter regulations to geopolitical uncertainties - can prompt companies to rethink their production strategies. For example, relocating or expanding production capacity abroad can be a way to tap into new markets, stabilize supply chains and benefit from more favorable economic conditions. This underlines the fact that resilience is not just about enduring crises, but also about actively exploiting new potential and tapping into opportunities for sustainable growth.
The article is based on a presentation at the Oberflächentage 2024.
