Digitized shop floor brings 100% visibility for a plastic recycling company, UK

Digital Manufacturing Case Studies

Project Overview

Client Profile

RPET sheets manufacturer

Location

United Kingdom

Industry

Plastics product manufacturing

Inputs

Spreadsheet-based reports for inventory, raw materials, and supplier management

Deliverables

End-to-end customized manufacturing solution

Business Needs

The RPET sheets specialist had no real-time visibility of manufacturing processes, stock availability and production capacity.

They needed to:

Infuse digitization in entire manufacturing process
Integrate siloed data lying in disparate systems and get valuable insights to make informed decisions
Get real-time updates on raw materials, stock availability, plant productivity and delivery schedules

Challenges

Inaccurate and erroneous manual reports for raw material yield, storage capacity and plant productivity
Vague communication patterns between stakeholders, vendors and customers
Inflexible barcode and manual quality check processes

Delivered a customized solution to digitize the entire manufacturing value chain, smoothen vendor management and eliminate manual intervention.

Manufacturing Execution System

The project team mapped existing ‘As-Is’ process with required ‘To-Be’ process for glitch-free transition from manual to automated systems.
Understood the required project KPIs for different processes like vendor management, production planning and quality check systems.
Deployed Cloud-based Manufacturing Execution System to:
- Remove manual dependency, production stoppages and enhance production flow.
- Track quality and quantity of raw materials received from suppliers and usage on the shop floor.
- Streamline production schedule, set and meet delivery deadlines.
Built holistic MES reporting and interactive dashboard for real-time status visibility and automated alerts.
Maintained logs for quality checklists and regularly delivered accurate readings of quality audits.
Automated generation of packaging labels and various other delivery documents.
Integrated client’s legacy accounting system for hassle-free purchase order generation.