Large Edible Oil Manufacturer
Food & Beverage
Real-Time Production Monitoring for Edible Oil Packaging
Transforming Reactive Reporting into Proactive Production Management
Challenge & Solution
The Challenge
- The manufacturer faced multiple inefficiencies: production losses not matching standard plant capacity, reactive reporting without real-time visibility, inability to identify root causes of issues, and highly manual MIS reports preventing solid analytics. These challenges resulted in significant wastage and operational inefficiencies.
The Solution
- Implementation of Plast 4.0 real-time data collection system with custom dashboards, scheduled reporting, and smart alert notifications. The system provides instant visibility into production metrics and pinpoints operational issues as they occur.
Key Results
Measurable improvements achieved through our solutions
24/7
Real-Time Monitoring
Continuous production visibility
Automated
Daily Reports
Shift-wise production analytics
Instant
Loss Detection
Immediate issue identification
Multi-Vendor
Analysis
Packaging supplier performance
Implementation Details
- Real-time dashboard showing line status, production counts, and speeds
- Automated tracking of planned vs actual production
- Machine-wise performance monitoring with speed gauges
- Comprehensive production loss waterfall analysis
- Categorization of downtime by specific causes
- Integration with existing production lines
- Web-based access for remote monitoring
System Dashboard & Reports
Additional Benefits
- Significant reduction in oil packaging wastage
- Better tracking of material usage vs standards
- Vendor performance analysis for packaging materials
- Automated shift-wise efficiency reports
- Reduced manual effort in report generation
- Data-driven decision making capability
- Historical trend analysis for continuous improvement