ABOUT
At the intersection of innovation and manufacturing, our client, a prominent plastic manufacturer with nationwide reach and renowned for producing fully recyclable plastic containers, has emerged as a beacon of excellence. With a focus on superior functionality and captivating design in the industrial, agricultural, and food sectors, they have solidified their market position.
Operating state-of-the-art high-speed extrusion blow moulding facilities nationwide, the manufacturing leader exemplifies efficiency and precision in every aspect of their operations. Still, even the most advanced systems can encounter challenges in optimising workflows and enhancing productivity.
Seeking to optimise their service workflows, the mould manufacturer embarked on a journey to enhance visibility, transparency, and operational efficiency. The goal? To streamline the tracking of mould conditions and service history, ultimately reducing production expenses while improving quality assurance.
THE CHALLENGE: SCULPTING PERFECTION IN A SEA OF COMPLEXITY
The company’s plastic manufacturing ecosystem boasts eight simultaneous manufacturing lines, each reliant on meticulously crafted moulds. The repercussions of a minor defect in a mould reverberate through the entire production line, potentially resulting in the discarding of thousands of containers – an expensive outcome that they want to avoid.
The challenge lay in the close interaction between tool makers, mould setters, and production line leaders. A manual, paper-based system governed their quality checks, pre-planning, handovers, and post-mould run storage. Recognising the inefficiencies inherent in this approach, our client envisioned a digital transformation.
BEFORE FILE13: NAVIGATING THE CHALLENGES OF MANUAL MOULD MANAGEMENT
Before the era of FILE13’s mobile app our client grappled with several challenges:
- Uncertainty around mould changes
- Inefficient tracking of mould conditions and service history.
- Dependency on individual knowledge-based systems and cumbersome paper-based processes.
- Complications in pre-planning, handovers, and storage of moulds using antiquated paper methods.
OBJECTIVES: FORGING A PATH TO OPERATIONAL EXCELLENCE
The objectives were crystal clear:
- Attain control and visibility across their operations.
- Empower production line workers with direct communication channels for prompt reporting.
- Enhance transparency and responsibility.
- Establish comprehensive service history through job card service reports.
- Proactively detect mould issues to prevent production problems.
- Improve visibility of mould issues to avoid open concessions for multiple runs.
- Optimise the entire mould service workflow from pre-checks to production and beyond.
- The solution: Transformative power unleashed
Xactco stepped in with FILE13, transforming manual workflows and instigating a digitised shift in operations. At the heart of FILE13 lies its central dashboard, offering a granular account and automated reports of mould service processes and history.
The mould producer now orchestrates a production run seamlessly with FILE13’s mobile app:
- Operators scan the mould’s QR code using the FILE13 app on their mobile devices.
- Pre-checks are performed to identify potential issues and prevent delays or quality problems.
- Mould setters utilise FILE13’s digital checklists for precision and consistency.
- Deviations prompt immediate notifications to supervisors for swift resolution.
- Team leaders monitor and manage production runs through FILE13.
- Removal of moulds involves detailed documentation using the FILE13 app, capturing crucial information for analysis and future improvements.
- Early detection of mould issues is now a reality, leading to the proactive adjustment of workflows and streamlining of processes.
“Before FILE13, if there was a problem with a mould and the line needed to continue running, employees had to apply to management for a concession. This led to open concessions for multiple runs, as there was no visibility on factory problems until it was too late. By then the mould would have gone back into the store room and the problem would only surface during the next run.”
RESULTS: A REMARKABLE SURGE IN PRODUCTION EFFICIENCY, REDUCING COSTS
Since embracing FILE13, the company has witnessed a remarkable surge in production efficiency, translating into significant reductions in production expenses. Real-time prompts during mould runs have not only elevated problem resolution but also facilitated the early detection and identification of mould defects.
Data analysis and trend tracking have become instrumental in managing mould lifecycles. The shift from traditional knowledge-based systems to digital tracking has enhanced the manufacturer’s data utilisation, providing valuable insights for continuous improvement.
Improved accountability through signature capture and meticulous documentation has streamlined exception escalations and reporting mechanisms, resulting in decreased quality defects and ongoing improvements in tracking efficiencies and time management.
LOOKING AHEAD: A FUTURE FORGED IN DIGITAL EXCELLENCE
Adopting FILE13 has demonstrated how digital solutions can unravel operational challenges. For our client, FILE13 represents a tailored, flexible, and adaptive tool that significantly enhances their manufacturing processes, slashes costs, and lays the foundation for continuous improvement.
The journey doesn’t end here. Xactco will continue their partnership with the industry leader, focusing on tracking and analysing time efficiencies as the system matures. The rollout of FILE13 to a second division is already in progress, marking the relentless pursuit of excellence.
“FILE13 transformed our mould management, bringing customisation and flexibility that perfectly fits our manufacturing needs. QR code tracking and real-time alerts boosted our efficiency and cut production costs. Now, early detection of mould issues is the norm, empowering us to adjust our workflows proactively and streamline processes efficiently. It’s not just a tool; it’s a partner in our progress. Excited to keep improving with Xactco’s ongoing support!”
