The Italian manufacturing company SPAC, specialized in the production of anatomical polyurethane footbeds for sandals and removable insoles, faced the challenge of extracting detailed information from its dated machinery to optimize production processes and enhance the quality of the final product. They turned to Zerynth to implement a system enabling real-time and remote data acquisition, facilitating monitoring and control of costs, consumption, and production.

Automating this process was crucial to ensure fast and reliable access to information regarding the machinery’s functioning. Additionally, integrating the data with the management system was essential for more efficient and precise production flow management, also aiding in benefiting from the Industry 4.0 tax credit and optimizing overall production efficiency.

Zerynth implemented the solution for SPAC, involving the installation of the Zerynth Platform on three hot-press molding machines, including one machine already prepared for Industry 4.0. The utilization of Edge Devices enabled the extraction and sending of data to the cloud for visualization on dashboards and analysis.

The achieved results encompass:

1. Production Streamlining: Real-time monitoring optimized production processes and overall efficiency.
2. Quality Control: Specific sensors monitored processing temperatures, enhancing both product quality and operational efficiency.
3. Integration with the Management System: Interconnecting with the management software improved process management and enabled the benefit of the tax credit.

The implementation of control metrics and the precise collection of data from legacy machinery have significantly enhanced product quality management at SPAC. Adopting a production monitoring system has made data regarding produced units and work orders more visible.

Now, SPAC can estimate the production cost for each item through data monitoring. The integration of a machine prepared for Industry 4.0 with the Zerynth platform has enabled them to avail Industry 4.0 tax benefits, integrate data with existing management systems, and attain complete visibility into orders and production processes.