Italian industries often face the challenge of long machine setup times, which slow down production and create inefficiencies. But how can these challenges be overcome to optimize production processes?

The Zerynth Industrial IoT & AI Platform provides SMEs with a solution that allows real-time monitoring of machine setup times, helping to reduce them and improve overall production efficiency.

In this blog post, we explore a case study of a plastic injection molding company that chose Zerynth to tackle market challenges. Keep reading to find out more!

The Challenges

An Italian SME specializing in plastic injection molding faced a common industry challenge: reducing machine setup times to enhance production efficiency. However, the lack of a Manufacturing Execution System (MES) and a still-limited level of digitalization made this goal difficult to achieve.

Until then, processes were monitored manually, and setup time data was collected in a fragmented manner—often using paper notes or non-integrated tools. This resulted in limited visibility over machine operations, making it difficult to identify inefficiencies and recurring patterns. As a consequence, production management was reactive rather than proactive: optimization interventions came too late, and maintenance was often focused on emergency fixes rather than prevention. This led to delays, waste, and a reduction in productivity.

The Solution

To address these challenges, the company decided to implement Zerynth, revolutionizing how production data was collected and utilized across its 8 injection molding machines. Thanks to the platform and the interconnection of existing machinery—without the need for replacement—the company was able to start monitoring cycle times and machine operating states in real time.

One of the first changes was the transition from a fragmented management approach to a clear and structured production overview: all data was collected in a single platform, easily accessible by the team. This allowed them to accurately identify inefficiencies in setup times and determine the best optimization strategies.

Additionally, thanks to Zerynth’s advanced analytics tools, the company was able to identify recurring delays and setup phase patterns, enabling faster and more effective interventions.

Through the Rules Engine, production managers can now set alerts and notifications whenever power consumption exceeds a predefined threshold or when cycle times deviate from the standard. This enables them to intervene immediately at the machine level, preventing slowdowns.

Real-Time Alerts for Immediate Action

In the world of industrial manufacturing, reactivity is key to avoiding machine downtime, waste, and inefficiencies. With the Zerynth platform and its AI-powered Rules Engine, companies can configure custom alerts to automatically monitor every phase of the production cycle.

This means receiving instant notifications in case of anomalies, such as power surges or irregular cycle times, allowing operators to act before these issues escalate.

By implementing intelligent alert systems, companies can reduce reaction times, prevent damages and additional costs, and focus on high-value strategic activities without the need for constant manual data monitoring. AI also enhances anomaly detection, providing a clear and detailed overview of production status.

To optimize energy costs and ensure efficient factory operations, it is crucial to have a platform that enables real-time energy monitoring of production, tracking the power consumption of machines in operation and ensuring they do not exceed the contractual limits. Staying within these thresholds helps prevent penalties or increased tariffs, which could significantly raise energy costs.

Not only was this functionality crucial for each individual machine, but also for each specific production process, providing granular visibility into machine conditions throughout the manufacturing cycle.

The Results

✅ 15% reduction in setup times

Immediate visibility into setup times, machine downtime, and activity periods

✅ 20% increase in operational efficiency

Elimination of inefficiencies and transition to a fully digital process

✅ ROI achieved in under 3 months

Rapid solution implementation with immediate benefits

Why Did the Company Choose Zerynth?

Beyond the measurable results, the company chose Zerynth for its flexibility and quick implementation. Unlike other solutions, Zerynth enabled digital transformation without replacing existing machinery, reducing both adoption time and costs.

Moreover, the platform offered a modular and scalable approach, perfectly adapting to the company’s needs and ensuring a progressive growth path. The ability to collect and analyze structured data provided the company with a new strategic vision for production, making management more efficient and responsive to market demands.

With this enhanced operational visibility, the company successfully implemented targeted strategies to reduce setup times, optimize production, and minimize waste.

The result?

A smoother workflow, fewer interruptions, and full control over the production process.

Thanks to Zerynth, the company turned a challenge into an opportunity for improvement, achieving tangible and measurable results within the first few months of use.

Want to optimize your production efficiency? Contact us today!