Reducing Waste and Maximizing Efficiency in Manufacturing

By Steve Bieszczat, chief marketing officer, DELMIAWorks

When processors and manufacturers think about conserving valuable resources, they are not only considering energy; they’re also looking at raw materials, time and people. The following are three real-world examples of how companies are using their manufacturing enterprise resource (ERP) systems to reduce waste while maximizing efficiency.

Lower Use of Raw Materials
Comar is a manufacturer of plastic packaging products and components for medical, pharmaceutical, healthcare and other markets. With facilities across the United States and Ireland, the company relies on real-time monitoring in its DELMIAWorks manufacturing ERP software to gain insights into how every machine in each of its production centers is operating. By monitoring production variances, defects can be adjusted out to increase yield while decreasing waste.

In addition to cutting scrap and driving efficiency, Comar is leading innovations in sustainable packaging. For example, the firm has collaborated with equipment vendors to improve process control on creating a new injection stretch blow molded bottle for gummy vitamins, and it has been able to reduce the amount of resin needed per bottle by up to 20% depending on the bottle size.

“‛Sustainability and Reduce, Reuse, Recycle’ are core to many of our customers’ value propositions,” said Comar Executive Vice President of Sales and Marketing Scott Conklin. “We are using insights from our DELMIAWorks system to help introduce new products that support their initiatives.”

Address Under-Performing Machines Faster
Gamsee Industries (Victoria) Pty. Ltd. is a supplier of high-quality plastic products throughout its customer base across Australia, which has continually reinvested in all-electric molding technology for its energy efficiency, precision, speed and cleanliness.
Gamsee also relies on real-time production monitoring in its DELMIAWorks manufacturing ERP system to immediately red-flag injection-molding jobs that are running outside of the cycle-time specifications for that particular job, so the team can make adjustments. “For example, when a press is running in the green on the real-time monitoring screen, that’s good because it’s running right on time,” explains Gamsee General Manager Kris Juzva. “But, when the press shows red on the screen, that’s a problem and a fire that needs to be put out.”

Juzva adds, “With the ability to forecast, track and monitor injection-molding production, we minimize waste – both material and human resources – enabling us to maximize resource utilization.”

Reduce Time Demands on Employees
PAC Strapping Products, Inc., is a full-service master distributor and manufacturer of plastic and steel strapping, systems, tools and accessories, which relies on the DELMIAWorks manufacturing ERP system to increase office employees’ productivity.
One area is maintaining individualized pricing for each customer. Previously, a PAC employee working 40 hours per week took two and a half to three weeks to manually update pricing for each customer. Now, the inventory module, which also handles pricing, automates most of the work and the process takes about two hours.

“I can’t tell you how much the inventory module in DELMIAWorks has helped us to maintain our margins by quickly updating prices for our customers to align with the new costs,” notes PAC Vice President and General Manager Marc Albero. Similarly, billing used to be a four-hour manual exercise. Now, using the ERP invoicing module, a PAC employee can verify the packing slip, inventory and whether the order has shipped – cutting the billing process to just 15 minutes.

These are three examples of how processors and manufacturers are automating their shop floor and business processes to reduce waste while protecting the resources, which are key to growth and profitability. Armed with data-driven insights, the potential to optimize operations further is nearly limitless.

Steve Bieszczat is responsible for DELMIAWorks brand management, demand generation and product marketing. Bieszczat’s focus is on positioning DELMIAWorks with the strategic direction and requirements of the brand’s manufacturing customers and prospects.
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