In the world of metalworking—an industry long recognized as vital to Italy’s economy—tracking production has become indispensable for making strategic decisions.

In this post, we’ll look at an Italian SME specializing in metal structures that struggled with production tracking until it turned to Zerynth for advanced operational control and process optimization. Read on to learn more!

The Challenges

A small company manufacturing metal fixtures for the furniture industry found it hard to understand daily—and especially monthly—production trends. Their primary need was to trace every step of the production process, not only on industrial machines but also at each manual workstation, with the goal of automating as much as possible and simplifying production scheduling.

They sought a production monitoring solution that was easy to implement, integrated with their existing ERP, reduced manual data entry and, at the same time, helped minimize machine downtime. Without a centralized system, identifying inefficiencies and monitoring work in real time was nearly impossible. Manual record‑keeping—whether on paper or in spreadsheets updated only at shift’s end—led to delays and inaccuracies when analyzing workflows. Moreover, the lack of structured downtime causality data prevented timely interventions to shorten idle periods and boost overall productivity.

The Solution: Zerynth’s IoT & AI Platform

To meet these needs, the company adopted Zerynth, an IoT & AI solution designed to digitize production and deliver advanced operational oversight. A phased rollout ensured no disruption to daily activities and allowed operators to embrace the new system naturally. Thanks to an intuitive HMI, workers now log every task directly at the machine with a few taps—eliminating end‑of‑shift manual entries and extending live monitoring to manual stations as well.

The HMI displays detailed job‑tracking data and lets operators start or stop tasks with a single touch. A dedicated downtime screen highlights interruption causes, enabling historical analysis and rapid corrective action. Zerynth’s advanced KPI dashboards give management clear visibility into idle times, categorize stoppages by root cause, and supply the tools needed to optimize production processes.

By leveraging the tablets already on site, the company avoided the expense of new hardware and sped up technology adoption. Integration with existing management systems unified data collection and provided a comprehensive, real‑time view of production. The platform’s downtime‑causation feature makes it easy for operators to report interruption reasons as they occur, empowering production managers to streamline workflows and eliminate bottlenecks.

Continuous monitoring and a user‑friendly interface have enabled the company to tighten setup times, reduce unplanned downtime and make better use of resources—ultimately simplifying production tracking, optimizing processes and improving overall efficiency.

Results

• 20% reduction in setup time, boosting operational efficiency and cutting tooling adjustments.
• 35% decrease in unplanned downtime, thanks to instant root‑cause identification and the adoption of predictive maintenance strategies.
• 25% increase in operator efficiency, by slashing manual data‑entry time and streamlining daily tasks.

Why Zerynth?

The company chose Zerynth for its scalable, intuitive production monitoring solution that required no overhaul of existing infrastructure. Seamless integration with legacy systems eliminated the need for costly tech upgrades, while re‑using on‑hand tablets maximized prior investments and minimized operator onboarding time.

Zerynth’s consultative approach and platform flexibility allowed the SME to roll out new features gradually, driving continuous performance improvements and ongoing production optimization. By combining advanced monitoring, an intuitive interface and structured data collection, the company transformed raw production data into a strategic asset for growth.

Do you face challenges in tracking your production processes? Ask Zerynth how we can help—get in touch today!