Data-driven manufacturing

A manufacturer of plastic components. The company carries out both mass and custom production, operating in an environment with high quality requirements, short lead times, and the necessity for precise management of raw materials and formulations.

Business challenges

The scale of production and the diversity of formulations required full integration of production, logistics, and quality areas. The client’s key needs included:

  • Integration with the injection molding machine data reporting system
  • Flexible planning and scheduling of production orders
  • Automatic labor reporting for machine operators
  • Increasing the effectiveness of maintenance activities
  • Real-time quality control on production lines
  • Optimization of raw material and warehouse logistics

Scope of implementation and transformation

Production management based on real data
A solution was developed to enable comprehensive management of the entire production cycle — from order intake, through scheduling, to production reporting. It allows dynamic planning of raw material consumption based on individual formulations, integrating with terminals at the machines and automatically retrieving data from the GOLEM system. This data is used to generate dashboard analyses and reports supporting management decisions.

Progress monitoring and automated reporting
Designed touch applications guide operators through the production tasks, automatically collecting data from the machines. The system also enables precise tracking of raw material usage — identifying batches at the level of individual bags, which is critical for custom production.

Integrated quality management and maintenance
Terminals allow technical issues to be reported directly from the production floor. Additionally, the system automatically generates maintenance requests based on detected anomalies. This enables rapid response from technical teams. Management of injection molds has been fully integrated with task scheduling and maintenance tracking, significantly reducing downtime.

Automated production and warehouse logistics
Modern raw material and finished goods warehouse management enables efficient batch identification, material flow tracking, and quick order picking. Mobile data collectors provide full control over warehouse locations, speeding up logistics processes and eliminating errors.

Sales and customer service support
An integrated database gives sales teams real-time access to order statuses and estimated completion dates. Monitoring the status of order picking and shipments facilitates priority adjustments in customer communication, significantly improving service quality.

Business outcomes

increase in operational efficiency
10 %
thanks to process automation and better production control
faster quality defect detection
10 %

due to immediate response to production floor data

fewer complaints
60 %

resulting from improved quality control and raw material traceability

reduction in material waste
10 %

through precise management of formulations and batches

customization to the client’s production specifics
0 %

thanks to an individually tailored system integration

Industry
DIY
Processes
big dataBusiness analyticsIIoTroboticssmart factoryWMS
Processes
big dataBusiness analyticsIIoTroboticssmart factoryWMS

implementationsOther examples

AdobeStock_1089731548
flexible production linesprocess automationprocess digitalizationsmart factoryWMS
A smart factory built on flexible production lines and process automation creates an advanced industrial ecosystem for the automotive sector.
AdobeStock_897233852
big datacyber-physical systemsinteroperabilityMESpredictive analytics
Cyber-physical systems and MES ensure smooth production control, predictive analytics and machine learning enhance efficiency, while interoperability and cybersecurity safeguard operational integrity.
AdobeStock_874880450_small
big dataBusiness analyticsIIoTroboticssmart factory
A smart factory based on robotics and IIoT enables efficient plastics production, supported by business analytics, Big Data, and resource identification through Auto ID.
AdobeStock_950491957
CRMdigital transformatione-commerceMESprocess automation
MES and process automation provide digital management of textile manufacturing, while e-commerce and CRM efficiently connect production to the market, enabling full system integration within the framework of digital transformation.
AdobeStock_1073351471_small
auto IDBusiness analyticsindustry 4.0supply chainstouch terminals
The digitalization of processes and touch terminals streamline production and warehouse management, while Auto ID and supply chains ensure complete goods flow control, supporting business analytics and the implementation of Industry 4.0 standards.

contactDiscover how Intelo can transform your business!

Contact us today to learn more and begin your business transformation. Together, we will create the future – and it starts now!

Telefon

+48 42 9420020

Intelo Sp. z o. o.

+48 42 9420020

Brukowa Business Center
ul. Brukowa 12
91-341 Łódź

Email
Social network

Inquiry

Leave your details, and our experts will take care of the rest.
Please enable JavaScript in your browser to complete this form.