Manufacturing companies face invisible challenges every day, but new technologies can help overcome them.

In this blog post, we’ll explore a case study from a company in the plastics sector and see how, thanks to Zerynth technologies, it tackled and solved traceability issues in its production processes.

Keep reading to find out more!

Operational Context

In this scenario, a single machine completes the entire processing cycle required by one work order without interruptions and within a single production shift. This is the most straightforward and common setup in production environments with continuous, low-variability processes.

Main Challenge

In a company operating in the plastic injection molding sector, the main challenge was not the technical complexity of the production process, but rather the need to ensure full digital consistency across all production systems. Each work order must be accurately tracked—from its creation in the ERP system to the completion of the production cycle and data transfer to the cloud.
However, traceability can be compromised by critical issues: delays in start signals, misalignments between ERP systems and machines, or inconsistencies between edge-collected data and cloud data.

The real issue lies in the lack of unified visibility across the entire information and production chain. Without precise synchronization, there’s a risk of improperly registered orders, fragmented data, or even worse, a loss of control over ongoing processes. An invisible challenge—but one that directly impacts quality, efficiency, and responsiveness to market dynamics.

Implemented Solution

To address the challenges related to data consistency and real-time production monitoring, the company chose to implement the Zerynth Platform—an end-to-end solution that natively connects management systems, production machines, and the cloud.
This implementation enabled complete monitoring of energy sources, production data, and machine operational status, integrating all levels of the production chain.

A crucial component of the solution was the use of Zerynth’s Work Order Management App, which allowed the company to structure and synchronize production cycles efficiently. The platform’s middleware directly receives work order data from ERP and MES systems and sends it to edge devices installed on the presses.
To overcome difficulties in collecting reliable data and maintaining constant production control, the company adopted a solution that connects all levels of the production process—from machines to management systems to the cloud.

Thanks to this integration, it’s now possible to monitor, in real time, not only the status of the machines but also energy consumption and production performance. Everything is fully integrated, providing a complete and constantly updated view.

The Work Order Management App was a key element of the project. It enabled better organization of production cycles, keeping everything in sync. Work order data is sent directly to the devices installed on the machines, which collect real-time information such as the number of items produced, energy consumption, and machine status—ensuring full control at all times.

Operators can easily start or end a production cycle directly from the machine via the Zerynth HMI panel, even in special situations. Once a cycle starts, data is automatically sent both as event-based updates (providing a snapshot of production progress) and as continuous data streams. Everything is linked to the same work order, ensuring coherence and transparency throughout the process.

Results Achieved

This scenario served as the foundation for validating the entire system. Accurate work order tracking from start to finish, reliable machine-level data collection, and intuitive visualization through the Zerynth Platform confirmed the robustness of the implemented architecture.

The solution proved not only effective in addressing the initial challenges but also scalable and replicable, providing a blueprint for managing more complex and diversified production scenarios.

Thanks to the integration of the Zerynth Platform, the company achieved:

• +25% improvement in work order traceability accuracy
• -30% reduction in downtime response times
• +20% improvement in energy efficiency due to detailed and continuous monitoring

These results demonstrate how adopting an integrated platform can lead to tangible, measurable improvements in the management of production, quality, and resources within industrial environments.

Key Benefits

✅ Reduced manual workload: no extra operator input required
✅ Automatic and accurate detection of good/scrapped parts, energy consumption, and processing times
✅ Integration with ERP/MES via middleware that synchronizes work order and production phase data

Ready to start monitoring your production and gain full visibility? Contact us today for a free initial consultation!