The growing complexity of production systems and the need to maintain high quality and efficiency standards pose significant challenges that require companies to have full visibility of their production processes. Manufacturing process optimization and analysis thus become important for maintaining a competitive advantage.

The Zerynth IoT & AI Platform is designed to allow industrial companies to monitor and optimize every phase of production in real-time, while also simplifying data collection and analysis. This approach allows for obtaining valuable insights to continuously improve operational efficiency.

Want to discover how the Zerynth IoT & AI Platform can transform your production processes and strengthen your competitiveness? Keep reading!

What is manufacturing process optimization and analysis?

With manufacturing process optimization and analysis, we refer to the set of practices and technologies aimed at examining, evaluating, and improving the efficiency and effectiveness of a company’s production processes. This approach aims to identify inefficiencies, eliminate waste, and maximize productivity, with the ultimate goal of improving product quality and reducing operational costs.

Rapid technological changes and increasing pressure on profit margins make manufacturing process optimization a strategic imperative. Companies that successfully implement these practices can enjoy numerous advantages:

• Increased operational efficiency
• Reduced production costs
• Increased production flexibility
• Greater market competitiveness
• Improved sustainability and reduced environmental impact

Challenges in the plastics sector

The plastics sector is representative of the challenges that modern industry faces. Two of the main challenges in the sector are high CO2 emissions and high energy consumption. These factors not only have a significant impact on the environment but also heavily affect companies’ operational costs.

Companies in the plastic production sector therefore face a dual challenge: reducing the environmental impact of their activities to respond to growing regulatory and social pressures, and containing costs to remain competitive in the market.

Industrial production efficiency is therefore a primary objective for these companies, which must optimize their processes, reduce energy waste, and minimize emissions, without compromising the quality of their products or overall productivity.

Zerynth Platform: the answer to production challenges

The challenges of the plastics industry make immediately clear the importance of effective manufacturing process optimization and analysis. Establishing and managing these processes might seem difficult, but technology comes to our rescue.

The Zerynth IoT & AI Platform offers a cutting-edge solution for manufacturing process optimization and analysis, allowing companies to monitor, analyze, and optimize in real-time every aspect of their production process. The platform makes it easy to collect and analyze large amounts of data, allowing for the generation of valuable insights useful for continuously improving operational efficiency.

Figure 1- Energy consumption dashboard in the Machine Monitoring App

The Machine Monitoring App allows tracking of energy consumption and CO2e emissions of both individual machines and the entire plant, enabling effective addressing of the above challenges. This allows for optimizing production processes based on collected data and obtaining several benefits:

• Identification of waste areas: Continuous monitoring allows for quickly identifying inefficiencies and promptly intervening to reduce energy waste.
• Reduction of production waste: Data-based process optimization allows for minimizing waste, thus improving overall efficiency.
• Positive impact on costs and emissions: optimizing operational efficiency allows for reducing operational costs and emissions, contributing to more sustainable production.

A Digital Transformation Story: The Armal Case Study

Armal is a concrete example of the benefits brought by manufacturing process optimization and analysis.

Armal is a company specializing in the production of plastic components. Armal was facing significant challenges related to the efficiency of its industrial production, particularly regarding machine performance monitoring and energy consumption control.

Thanks to Zerynth and the implementation of the platform, Armal managed to radically transform its production processes. The company implemented a real-time monitoring system that allowed:

• Constant monitoring of machine status (on/off/alarms)
• Real-time monitoring of energy consumption
• Analysis of production performance (number of injections, cycle times, automatic and manual production times)
• Comparison of current data with historical data to identify trends and anomalies

Through the Zerynth solution, Armal carried out targeted optimization interventions, managing to reduce machine energy costs by 40% and recovering the investment made in IoT & AI technology in just 4 months. Furthermore, the company gained unprecedented visibility into its production processes, allowing for strategic decisions based on concrete and real-time data.

Want to discover more success stories like Armal’s? Visit our case studies page to learn more!