Case Study

The Rigid Plastic Company

The Commercial Printing Company kept records of their processes and workflow manually, consuming a lot of time and resources.They also struggled to reduce downtime of critical equipment due to lack of shop floor operations visibility

Seeing Challenges as Opportunities

The Rigid Plastic Company faced challenging and increasing delivery costs. Unable to identify the root causes for unexpected downtime, machines often had to be shut down for long periods leading to high levels of waste, increased costs and a negative impact on quality and equipment effectiveness.

Unplanned Downtime

Frequent and unplanned downtimes were often difficult to predict with no clearly identifiable root cause.

High Levels of Waste

Downtime led to high levels of waste across the production and manufacturing process.

Lower Levels of Quality

Quality and overall equipment efficiency was low and needed to be optimised.

How O3ai Enabled Smarter Manufacturing

We deployed the following solutions to help RPC achieve the desired results:

O3ai Advanced Analytics

To identify key process parameters and their effect on quality. These provided operators with early warnings against breakdowns, to ensure corrective actions and reduce unplanned downtime.

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O3ai Progressive Maintenance

To take proactive actions before failure, and streamline the maintenance process.

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O3ai Production

To connect and monitor its utilities and machines, this provided visibility into key parameters at each stage of utility operations.

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O3ai Impact

The Rigid Plastics Company were able to exceed their targets and improve their performance and key parameters, most notably by:

Improved Delivery Performance OTIF
Reduction in Unplanned Downtime
Reduction in  Waste
Reduction in Customer Complaints
Improved Delivery Performance OTIF