Tecnotri
Data:
October 2019
Category:
MES
Client:
Tecnotri
The Company
Founded in May 2001, the TECNOTRI INDÚSTRIA DE PLÁSTICOS manufactures a complete line of products for internal, external, and reverse logistics, using a manufacturing process known as plastic Rotomolding. With high-quality materials and cutting-edge technology, Tecnotri creates solutions to increase safety, productivity, and efficiency in companies across various sectors: industrial, automotive, chemical, agricultural, construction, pharmaceutical, hygiene and cleaning, food, and environmental.
THE CHALLENGE
Since Tecnotri's foundation, we have always had a special focus on the efficiency of our production because we understand that the more efficient we are, the better the delivery to our customers will be. Over the years, we have created various indicators to measure efficiency such as available hours vs. hours worked, processed weight, among others. However, our major difficulty has always been the quality of information because we extracted data from the ERP, which provides theoretical production data, and also from parallel control spreadsheets. Another issue is that collecting this data and transforming it into indicators was very labor-intensive, and we only had updated information once a month. Until 2017, when we were selected to participate in the Scale-Up Industry program organized by Endeavor, where we had a closer contact with the concepts of Industry 4.0.
THE SOLUTION
We came back convinced that it was possible to start Tecnotri's journey towards Industry 4.0 and called Allcance Technology, which has always been our partner, for a meeting. In this meeting, we learned that Allcance had been conducting research in this area for many years. Therefore, we immediately agreed that they would develop the Allcance MES Manufacturing Execution System (MES), and we would assist with our knowledge of the Rotomolding process and provide our infrastructure for testing. The development was very fast; within 7 months, we were conducting the first data entry tests, and 3 months later, we were monitoring all our machines.
From then on, we started monitoring our entire production process from start to finish, 24 hours a day. Today, we have reliable indicators available in real-time to improve our productivity. We have spread televisions with dashboards throughout the factory, PPC room, and management office. This visual management allows us to identify problems the moment they occur and seek immediate solutions to resolve them.
We also have access to historical data on reasons for downtime, efficiency, and non-conformities by machine, operator, shift, product, among others. This allows us to prioritize actions and monitor their effectiveness. These pieces of information have already justified costly adjustments in molds and the acquisition of RWTC due to raw and burnt parts, for example. Operators are aware of their goals and daily demand solutions from us to improve their performance.
With the implementation of Allcance MES, we were able to create a culture of continuous improvement at Tecnotri.
RESULTS ACHIEVED
Our satisfaction with Allcance MES is 10 out of 10 because our efficiency has been increasing every day, helping us to be more competitive in the market. Below, we will list just a few of the gains we have already achieved:
- Creation of a culture of continuous improvement;
- Elimination of data collection activity and indicator feeding;
- 60% reduction in machine downtime;
- 50% reduction in non-conformities;
- 45% reduction in setup time;
- 53% increase in OEE (Overall Equipment Effectiveness);
- 20% increase in processed weight.
COMPANY DATA
Address: Rodovia RS 324, Km 75, No. 1001, PO Box 07
Neighborhood: Distrito Industrial
City: Vila Maria – RS
Phone: (54) 3359-2400
Site: www.tecnotri.com.br