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Description
Plastics Kotronis S.A. manufactures exclusively plastic containers and lids suitable for food packaging (yogurt, feta, salads, etc.) using injection molding machines, while over the last decade it developed an expertise in decorating containers with polypropylene (PP) labels by using In-Mold-Labeling (IML) technology.
KIMA 4.0 is a project related to the implementation of Industry 4.0 principles in a manufacturing company. The project will use hardware and software to collect real-time data from the manufacturing process (replacing the current state of manual, handwritten data collection process), that will enable further analysis to inform decision-making, increase productivity and efficiency and optimize the manufacturing process. All injection moulding machines in operation will be interconnected (through hardware and software) and transmit real-time data related to their operation via the Manufacturing Execution System (MES) for further use and analysis within the company. All key stakeholders within the company will therefore have access to real-time and reliable data related to performance and efficiency.
KIMA 4.0 will reduce overall energy consumption in production, reduce scarp rate and improve the production efficiency. It will reduce the production costs, create 5 new fulltime positions, and increase the company’s revenues and competitiveness.
Summary of project results
The project achieved the results that were expected during application. The hardware and software for the monitoring of the production is now in place and operational, replacing the need to manually keep track of the production process. The digitalisation is in place but the full results have not yet materialised as the new way of operating the production management and monitoring is gradually being rolled out. However, there is already a decrease in scrap during the production, there is an observed decrease in the downtime of the machines and there is a reduction in the workload of the planning staff and the shopfloor staff. In addition 5 new jobs have been created as part of the project and will be retained even after the project is completed. The project is also expected to contribute to an increase in the turnover and net operating profit for the company, something that will be visible in the 2023 financial results as well as in the future.
The full results of the project and the digitalisation of the monitoring of the production will be observed during the months to come.