PLASTICS
UROLA OPTIMIZES THEIR PROCESSES THANKS TO AGILE DECISION MAKING
Urola, part of Mondragon Corpporation, is a leader in blowing technology since 1975, and is directly present in 4 continents.
Beyond developing advanced solutions for can & bottle manufacturing, they are also manufacturers of plastic containers and molds for the food sector and others.
CHALLENGE
Urola identified the challenge of digitizing their plant much earlier than the majority of industry players in their sector.
Despite having worked thoroughly on improving the efficiency of their plant and equipment, without the required digital solutions, many emerging key questions were often hard to address quickly and accurately.
Urola's challenge consisted on integrating work order management with production line OEE, combining both with real-time process data. This would allow tracing production incidents and provide both the QC deparment and other system users with quality information and data, thus creating an environment that bolsters agility and grants focus at the time of making decisions.
SOLUTION
With the Savvy SmartBox, we have been able to connect to every machine in all lines, and interoperate with the various ERP systems in Urola plants.
Urola contacted us seeking a solution for their digital challenges. After a number of workshops, we jointly agreed that designing a hybrid solution was necessary, comprising Savvy Edge & Cloud technologies.
Collected data is relayed to the Cloud securely, where a a multitude of key performance displays are automatically generated, geared towards both executives as well as any other role in the company:
- Machine / Fleet OEE, complete with breakdowns of availability, machine stops, performance and quality - traceable by shifts and work orders.
- Correlation between production stops and machine alarms.
- Management of energy consumption and raw materials.
- Management of process parameters.
- Equipment condition monitoring & analysis.
RESULTS
Urola now posseses an integrated platform that monitors, analyzes and suggests points of improvement.
Thanks to Cloud technologies, we have automated periodic (weekly, monthly) reporting with aggregated information about production and machine condition, achieving:
- Higher degree of control over plant productivity and performance of production equipemnt.
- Quality, up to date information for innovation and improvement deparments, granting a key tool for process knowledge and optimization.
- Greater understanding of key factors of non-quality related costs.
- Improved decision-making based on real, accurate data.