Case Study: Polyhose revolutionizes manufacturing with SkyMes – mastering production, SPC, and material tracking
Sector: Rubber & Plastics
Introduction
Polyhose, a global leader in manufacturing flexible hoses and fluid conveyance systems, serves diverse industries with a comprehensive range of products, including thermoplastic, rubber hydraulic, PTFE, and industrial hoses. To maintain its competitive edge and meet stringent industry standards, Polyhose sought to enhance its production processes, implement robust statistical process control (SPC), and improve material tracking capabilities. The implementation of SkyMes, a state-of-the-art Manufacturing Execution System (MES), provided the solution to these challenges.
The Challenge
Polyhose faced several operational challenges that impacted its efficiency and product quality:
Production Inefficiencies: Manual monitoring of production processes led to delays and increased the likelihood of errors, affecting overall productivity.
Lack of Statistical Process Control (SPC): Without SPC, it was challenging to monitor process variations, leading to inconsistencies in product quality.
Inadequate Material Tracking: The absence of a comprehensive material tracking system made it difficult to trace raw materials through to finished products, complicating quality assurance and inventory management.
The Solution
SkyMes provided Polyhose with a comprehensive MES tailored to address these specific challenges:
Enhanced Production Monitoring: SkyMes offered real-time monitoring and control of production processes, enabling immediate detection and correction of deviations, thereby improving efficiency.
Implementation of SPC: By integrating SPC tools, SkyMes allowed Polyhose to monitor process variations statistically, ensuring processes remained within control limits and enhancing product consistency.
Comprehensive Material Tracking: SkyMes facilitated end-to-end material tracking, providing complete visibility from raw materials to finished goods, improving traceability, and ensuring compliance with industry standards.
The Results
The implementation of SkyMes led to significant improvements for Polyhose:
Increased Production Efficiency: Real-time monitoring reduced production downtime by 25%, leading to higher output and better resource utilization.
Improved Product Quality: The adoption of SPC reduced product defects by 30%, ensuring higher customer satisfaction and compliance with industry standards.
Enhanced Traceability: Comprehensive material tracking streamlined inventory management and facilitated quicker response times to quality issues, enhancing overall operational efficiency.
Conclusion
Polyhose's integration of SkyMes into its manufacturing operations has been instrumental in overcoming production challenges, implementing effective statistical process control, and enhancing material tracking. These advancements have led to improved efficiency, superior product quality, and strengthened Polyhose's position as a leader in the flexible hose manufacturing industry.
Company Website: Polyhose
