Production optimization, order tracking for visibility, and quality optimization

Streamlining production processes is among the main challenges faced by Italian companies in search of solutions that allow them to achieve full visibility of orders, product quality, and machinery maintenance.

A fashion manufacturing company that specializes in producing metal components sought a solution to monitor its diverse range of legacy machinery for customized processing tailored to each client.

The company’s main requirements included real-time order tracking throughout the production chain and accurate evaluation of the quality of the produced parts to reduce waste and optimize the entire production line.

Furthermore, the company required a reliable and real-time maintenance management system to minimize machinery downtime, improve production efficiency, and reduce costs and energy consumption.

The solution proposed by Zerynth involved the installation of the Zerynth Platform on legacy machines without PLCs, which were located in two different facilities.

By utilizing Zerynth’s Edge devices, it became possible to extract production data from the machines, including information on the quantity and quality of produced parts, alarms, and feeding phases.

The data is then processed onboard the machines and sent to the Zerynth Platform, where it is displayed on dedicated dashboards. This allows for the monitoring of energy consumption and costs across all machinery, as well as the analysis of inefficiencies.

The interconnection of legacy machinery in different facilities has allowed the company to achieve full real-time and remote visibility into the operations of their machinery.

Now, the company is able to track every order in real-time, obtaining information not only about the overall functioning of the machines but also about each order in the production chain. This enables them to immediately identify any inefficiencies and monitor the production time for each product, improving the overall process speed.