Off- Spec Prevention- Lower Rejects
Industry: Latex Gloves
Challenges:
- Losses in the compounding process e.g. batching error like temperature, dosing that leads to off-spec outcomes
- Discrepancies in tallying- raw material to throughput does not add up. Up to 30% lesser.
- Lack of automation on batching steps e.g. manual effort and decision making
Solutions:
- Step 1: Audit of existing process and instrumentation available
- Step 2: Recommend additional automation requirement to be deployed
- Step 3: Continuous monitoring of all steps and chemical usage with the respective throughput (Output)
- Step 4: Validation & AI Recommendation of Ideal Parameters
- Step 5: Application and Reporting
Outcome:
- Reduce Energy – save by USD 1,300 overall per month/ each month
- Reduce micro wastage due to uncontrolled manual dosing USD 13,000 raw material per month
- Improve Compounding Steps and timing in precise timing – Increase cycle time and output.
- Reduce “blending speed” inconsistencies – Reduce waste by USD 500/month.
- Energy waste from forgotten empty tank but steam/heating & stirrer turned on – USD 800/month.
Benefits to Client:
Zero manual reporting and process monitoring for the compounding process
Increased Cycle Time due to precision batching
Reduce wastage of energy and raw material wastage as well as eliminate discrepancies.
