+30%
increase in production volume
Project objective: +20% in productivity
Results
Context and challenge
A plant with two connected lines of PVC-coated fabrics, facing low demand and a high volume of complaints due to quality variability. High waste and daily production below potential pressured service and profitability. Operators changed formulations without formal criteria; outdated recipes and unclear SOPs; poor scheduling increased setups and waste; reports and meetings generated no insights, routines, standards and Data, Systems and AI applications were missing.
Approach and impact
Quality operating system
A daily cadence of KPI review with quality dashboards and root-cause analysis; formulation repeatability through short-interval control, updated SOPs and real-time parameter monitoring; procurement policies and formulation guidelines to reduce variability.
Data and digitalization
Operational and executive dashboards connected to the ERP, reducing spreadsheets; a streaming analytics platform to monitor formulations, machine alerts and automated statistical quality insights.
Production and planning
Planning redesign to optimize capacity, throughput and setups; critical SOPs (setup execution and raw-material inspection) reducing waste and stabilizing execution.
*Selected project result. Gains vary depending on context, maturity and scope.