Plastic and Resin Manufacturing: Use of Manufacturing Analytics on Factory Floor Increases Efficiency

Manufacturing is in the middle of an evolution, Industry 4.0. As big data grows in many industries, manufacturers are beginning to implement and use a multitude of software designed to create a smart, connected factory.

Implementing real-time manufacturing analytics on the plant floor has transformed many industries, and plastic and resin manufacturing is no exception. As we move forward in Industry 4.0, big data and manufacturing analytics have the power to help the plastics industry grow exponentially.

Looking back at the progress the plastics industry has made throughout the years is astounding. The first synthetic polymer was invented in 1869, and that discovery was transformative. Fast forward to today, and the plastic and resin industry is worth roughly $96 billion. The revolutionary progress is outstanding.

How does the industry continue to transform and grow? The answer is manufacturing analytics. Read along as we take a deep dive into the challenges facing plastic and resin manufacturing, the solutions manufacturing analytics has to solve those problems, and the benefits it can bring to the industry.

The Challenge: Plastic and Resin Manufacturing Lacks Visibility

Look around and you’ll see plastic everywhere – product packaging, medical devices, water bottles, the list is never-ending. Plastic is the third-largest manufacturing industry in the U.S. Yet, on the plant floor where those plastics are produced, there is very little visibility into the efficiency of those processes.

With the sheer amount of product containing plastic, there needs to be a way to ensure the plant floor, where those products are produced, is running as productive and efficient as possible.

 

The lack of visibility is transformed with manufacturing analytics. Knowing when machines are up or down, replacing Excel-based reporting, and being able to see and stop problems as they’re happening gives plastic and resin manufacturers the ability to make data-driven decisions.

If it sounds too good to be true, it’s not.

How Can Manufacturing Analytics Help?

Example 1: Consider a plastics mold that has 2 cavities and can create 2 bottles at a time. With SensrTrx, you can track that the machine cycled, and a machine makes 2 bottles. Note: The number of bottles in this scenario is just an arbitrary number, but the takeaway is that by using manufacturing analytics software, we can count both molds and parts, and track the cycles. 

Example 2: With SensrTrx, you will be able to track process data like pressure, vibration, or temperature. If a temperature dips below a recommended level, the software can alert you in real-time.

The Solution: Valuable Insights Change the Course for Manufacturers

Improving shop floor productivity through data and analytics is the first step in real-time monitoring. Manufacturing analytics solutions, like SensrTrx, can supply the software needed to collect valuable data that can identify areas for improvement, maximize resources, and provide ongoing visibility into the factory floor.

Using manufacturing analytics, identify trends, track key metrics, increase throughput, reduce waste, decrease downtime, integrate with maintenance seamlessly, and reduce costs.

With SensrTrx Lean, you can be online within a day and one step closer to a truly efficient shop floor. Begin collecting data on when machines are running and when they aren’t, performance, quality, and availability metrics, OEE, and so much more.

Manufacturing analytics can be the solution to the challenges you face on the plant floor. Start small, think big, move fast with manufacturing analytics in the plastic and resin manufacturing industry.

See For Yourself The Power of Plant Floor Visibility

Let us give you a customized demo of the software designed to address your visibility challenges. Learn how to address downtime, manage throughput and reduce scrap.