M.C.A. 4.0: AI in the Metalworking Industry with Zerynth
M.C.A., a leading company in metal stamping and mechanical assembly, has adopted Zerynth’s Industrial IoT & AI platform to digitalize its shop floor and enhance operational management. This transformation has led to more precise, faster, and sustainable production, successfully adapting to the new challenges of the metalworking sector.
15th november, 2024
The Italian metalworking sector represents a key component of the national economy. However, companies in this industry face growing challenges, including increasing demand for customization, rising energy costs, and the need to reduce product time-to-market. Artificial intelligence offers a viable solution for industries tackling these challenges.
AI adoption in the manufacturing sector is rapidly increasing due to the significant benefits this technology can bring to companies. According to a McKinsey report, integrating AI and IoT in production could boost productivity by up to 30% and reduce energy costs by an average of 20%, making companies more competitive and sustainable in an evolving global market.
In Italy, over 60% of metalworking SMEs have begun a digital transformation process, recognizing the importance of collecting and analyzing real-time data to improve operational decision-making and reduce downtime costs.
Founded over 40 years ago, M.C.A. Truccazzano has always focused on innovation and efficiency to stand out in the market. However, as demand grew and operational complexity increased, the company faced new challenges:
- Increasing visibility into machinery productivity
- Monitoring production remotely to avoid on-site inspections
- Reducing manual data entry operations
- Automating the reporting process
- Monitoring energy consumption
“At M.C.A., we manage complex processes and needed deeper visibility into our machinery to optimize production and intervene promptly,” says Massimo Forloni, CEO of M.C.A.
To address these needs, Zerynth implemented its Industrial IoT & AI Platform in M.C.A.’s production plant, connecting the machinery across the entire production floor, including presses, laser welders, riveting machines, and testing machines for solenoid valves.
The Zerynth Industrial IoT & AI Platform stands out for its ability to collect and analyze real-time data, supporting operational decisions 24/7 through automatically generated insights and suggestions. Zero, Zerynth’s Industrial AI Copilot, adds an advanced layer of artificial intelligence, transforming raw data into intelligent reports and enabling immediate action in case of inefficiencies or anomalies.
Thanks to Zerynth, M.C.A. reduced manual reporting operations by 30% and achieved full real-time visibility into production performance. Additionally, errors from manual data entry into the platform decreased by 90%, and operators gained 24/7 decision-making support through in-depth insights and intelligent suggestions provided by Zero.
In less than two months, the project was completed. Thanks to Zero, information from the machinery is immediately available to operators and managers, enabling real-time optimization strategies. The platform’s chat feature simplifies management, reducing the learning curve associated with IoT and AI technologies.
Zero, the Industrial AI Copilot developed in collaboration with Microsoft, assists users in data analysis and maintenance, providing real-time anomaly notifications via Telegram, Microsoft Teams, and email.
The interaction between users and AI becomes intuitive: natural language commands can be used to generate emails, reports, and tables, making it feel like a conversation between colleagues.
“Zerynth has allowed us to monitor data in real time and access this information remotely, overcoming the limitations of physical inspections and reducing manual data entry operations. This has transformed our operational approach, making it more precise, faster, and sustainable to better address modern market challenges,” Forloni adds.
The project, a finalist at the Digital360 Awards and presented at the METS (Milan Emerging Technology Summit), serves as a concrete example of how IoT and AI technologies can support manufacturing companies in evolving toward more efficient and sustainable production models.
About Zerynth
Zerynth revolutionizes industrial production with an advanced platform that integrates IoT and AI, facilitating the optimization of production processes and reducing energy consumption. Our mission is to enable companies in their digital transformation journey by easily connecting any machinery to a powerful Industrial AI system. With the launch of Zero, the Industrial AI Copilot, we position ourselves as leaders in the field of industrial AI, promoting production efficiency and sustainability.
Our platform allows real-time monitoring of machinery performance, advanced KPI analysis such as OEE, and predictive maintenance. Zerynth seamlessly integrates with ERP, MES, and BI systems, ensuring data security and rapid configurations thanks to the No-Code Configurator.
Founded in 2015 in Pisa, Zerynth serves over 150 client companies across various industrial sectors.
For more information: www.zerynth.com
Press Office of Zerynth
Alice Benozzi | communication@zerynth.com