Background
Mitsu Chem Plast Limited (Mitsuchem) is a 32 year old manufacturer of world class blow and injection molded plastic products. Using patented technology, Mitsuchem has established itself as a leader in automotive components, health care and hospital furniture, infrastructure/stadium furniture and industrial packaging solutions. They have multiple plants in India serving Indian and global customers. Mitsuchem has a culture of continuous innovation fueled by investments in best-in-class processes and technologies.
Challenges
Mitsuchem’s leadership aspired to achieve improved productivity and efficiency that would sustain the tremendous growth and expansion of their business despite the rapid pace of change and complexity in the global business environment. They identified Industry adoption as a key strategic enabler for their development.
Existing manual and semi-manual measures result in blind spots that limit the degree to which process productivity and efficiency can be improved. Manual data collection is also occasionally inaccurate leading to sub-optimal decision making.
Therefore, they were looking at Industry products to help them retain their competitive edge by enabling a culture of data-driven decision making and improvements.
Solution
axisPLAST , a premier and industry leading Industry product for plastics manufacturers, digitally enabled 22 blow molding machines across their 3 plants in the first batch to provide a single, integrated, multi-plant view of their operations across the organization. The timeliness, accuracy and depth of analytics uncovered opportunities for improvements that Mitsuchem team was hitherto unaware of due to limitation of manual, paper-and-spreadsheet based data collection and analysis.
For example, insights from axisPLAST immediately and accurately flagged inefficiency in ideal cycle time through continuous, near-real time monitoring of actual cycle time and trends over time.
axisPLAST downtime analytics which include total downtime loss, Mean Time Between Failure (MTBF) and Mean Time To Repair (MTTR) across machine, section and plant level enabled a deeper understanding of root causes for downtime. Mitsuchem team leveraged these analytics to proacticely put corrective action plans in place to significantly reduce downtime.
Benefits
The results within two years of adoption have been tremendous
- Improved operator and supervisor productivity due to reduced paperwork
- Increased customer confidence and satisfaction due to transparency and trust on data
axisPLAST adoption has validated Mitsuchem management’s vision and belief in benefits of adopting Industry technologies and helped them achieve the benefits they expected from the investment.
“axisPlast has met every expectation we had, and we continue to push the envelope to drive greater value for our business. In addition to delivering an excellent product, EcoAxis has been a true partner with their customer first approach which is essential to the success of any organization’s Industry journey. In the next phase, we plan to integrate axisPLAST with our ERP to improve our on-time, in full (OTIF) for enhanced customer satisfaction”
– Jagdish Dedhia, Chairman, Mitsu Chem Plast Limited
Customers Who Trust EcoAxis.
“We chose EcoAxis for its technological superiority, domain knowledge and experience in RPMS (Remote performance monitoring system) which make it a leader in the segment. EcoAxis team has a phenomenal ability to understand our needs and translate them into a reliable solution. We have already considered EcoAxis for 6 overseas projects and would not hesitate to recommend them to others.”
“Energy and operational efficiency improvements were our immediate business goals. We decided to go for EcoAxis’ solution digitizing our complete plant floor with access to analytics on anytime anywhere basis…we have achieved close to 15% energy efficiency…we are confident to achieve a further 10% improvement on energy costs in the current year…and are confident that we would be able to drive up to 10% OEE improvements at the factory level.”
“We are excited by the business gains and competitive edge that axisPLAST has helped us realize in such a short period. Also it will help us to continuously push the boundary of innovation to stay ahead of our competition. Industry being a strategic and an on-going program, it requires a trusted and knowledgeable partner like EcoAxis.”
“For our competitive advantage, we leverage the data of our interconnected machines, material traceability, and SAP business system for getting live KPIs anytime, anywhere, using EcoAxis’ IoT solutions. Our expectations from the IoT solution were very challenging, but I am happy that EcoAxis has surpassed our expectations.”
“We are delighted to see the latest enhancements in axisPLAST , especially the daily and monthly reports providing all relevant data that we need”
“We decided to use axisPLAST , the Internet of Things technology, provided by EcoAxis to collate and analyze live data. It has some unique functionalities built specifically for plastic product manufacturers, e.g. operational reports, mold analytics, etc. providing us tremendous value in terms of operational analysis.”
