PROJECT GOAL: 20% in Throughput
Operating two connected production lines for PVC coated fabrics, the plant faced a tough market: low demand combined with a high volume of customer claims driven by quality variability. At the same time, waste levels were high and daily output was below potential, putting pressure on both service levels and profitability. While dashboards existed, the operation lacked the management routines and standards needed to turn data into consistent execution and repeatable quality.
Quality & formulation control
Operators were changing production formulations frequently without clear, formal criteria—driving quality variability and customer claims.
Recipes were outdated, and SOPs for validating new raw materials and suppliers lacked clarity, increasing variation and decision-making friction.
Waste & throughput economics
Waste was high and daily output low, creating a direct drag on overall business performance. With raw materials expensive and difficult to source, waste became a critical constraint requiring immediate action.
Planning & execution
Poor production scheduling increased unnecessary setups and excessive waste, limiting throughput potential.
Performance management & digital enablement
Performance reports and management meetings were not providing the insights required to improve operational performance. There was a clear need to implement Industry 4.0 applications—KPIs, data collection, real-time monitoring, and automation—to support repeatable control at scale.
| Finance | +350% Return on Investment |
| Sales | +18% in Net Sales |
| Data & Systems | 80% KPI Reports Automation |
| Quality | 39% Quality Improvement |
| Maintenance | +15% OEE |
| Finance | 7 months Payback Period |
30% increase in throughput by implementing Industry 4.0 & Advanced Analytics Platform
We combined operational discipline with real-time visibility to stabilize quality, reduce waste, and unlock throughput across two connected production lines
Quality Operating System (routines + standards + repeatability)
Established a daily KPI review cadence supported by quality dashboards and root cause analysis (RCA) to drive faster, fact-based decisions.
Improved formulation repeatability through short interval control routines, updated SOPs, and real-time monitoring of machine parameters via dashboards.
Reinforced buying policies and formalized production formulation guidelines to mitigate quality variability and reduce the risk of off-spec output.
Industry 4.0 & Digitalization (automation + alerts + analytics)
Delivered ERP-connected operational and executive dashboards to automate reporting and reduce dependency on spreadsheets (“No Excel left behind”).
Implemented a streaming analytics platform enabling real-time monitoring of raw material formulations, machine alerts/notifications, and automated statistical insights to detect patterns and quality deviations.
Production & Operational Planning (less setup, more flow)
Redesigned the operational planning process to optimize capacity, throughput, and setups, reducing unnecessary changeovers.
Implemented critical SOPs (e.g., setup execution and raw material inspection) contributing to overall waste reduction and more stable execution.