Context
Polyhose manufactures flexible hoses and fluid-conveyance systems for many industries. Its range covers thermoplastic, rubber hydraulic, PTFE and industrial hoses, and its industry standards are demanding.
Challenge
- Manual monitoring. Production was monitored manually, which slowed the detection of deviations.
- No statistical control. Process variation was not tracked statistically, so quality consistency was hard to demonstrate.
- Incomplete material tracking. Tracing raw materials to finished products took effort, for both quality assurance and inventory.
Architecture
- Metalya Core: real-time monitoring and control of production.
- Quality & Process Control: statistical process control on process parameters, with control limits and alarms.
- Materials & Traceability: lots followed from raw material through production to finished goods.
Implementation
Monitoring, SPC and material tracking were introduced on the same production model. A process deviation and the lots it affects are read in one context, without reconciling separate tools.
Result
- Deviations are detected and acted on while production runs.
- Processes are kept within statistical control limits.
- Traceability from raw material to finished hose supports compliance and a faster response to quality issues.
Evidence
The published case study reports reductions in downtime and defects. These figures are awaiting customer approval for this site.