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

Digital Manufacturing Case Studies
Digitized shop floor brings 100% visibility for a plastic recycling company, UK

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

Our Solutions & Approach

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

Share Your Thoughts
manufacturing-execution-system
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.
Production Chart
Production Chart

Business Impact

Project Samples

Financial Dashboard
Financial Dashboard
Production Planning
Production Planning
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