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Networking of all machines - despite different ages, sizes and functions

Plastic packaging manufacturer relies on systems from WERMA and optimises its production within just a few weeks.

The Dutch company FLESTIC specialises in intelligent plastic packaging solutions and produces bottles, pots and caps as well as customised plastic packaging. Machines of different ages, sizes and functions are used for this purpose. Until now, the company has not been able to determine precise key figures on capacity utilisation, order status or productivity.

Customer

Flestic

Industry

Packaging solutions

System solution

MDE-System

Highlights

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Clear status display: Visual signal towers show machine status in real time and transmit data centrally.

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Easy networking: The MDE system networks machines cost-effectively and independently of their age or manufacturer.

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Productivity increase: Faster fault detection, shorter response times and less downtime increase efficiency.

Task
Solution
Result

Task

Flestic uses machines of different ages, types and manufacturers. As a result, it has not yet been possible to determine precise key figures for capacity utilisation, order status or productivity. In addition, it is not possible to see when a machine is started or stopped or what the reason for this interruption was.

Machine status display - Visual and digital
Quick response in the event of malfunctions and breakdowns
Determination and analysis of reliable key figures
Increase machine utilisation and productivity

Solution

The company came across the machine data acquisition system (MDA system) from WERMA. This process optimisation system consists of a radio transmitter, radio receiver and software. The radio transmitter is simply integrated into the existing WERMA signal tower as an additional element via Plug & Play and monitors the status or quantities of machines, systems and manual workstations.

These statuses are transmitted by radio to the radio receiver, which transmits all data seamlessly and saves it in a Microsoft SQL database. The status of each machine is displayed visually using the three-stage signalling columns: The red light indicates that the machine has stopped, yellow lights up if the temperature difference is too great and green signals a smooth process. Of course, these are also transmitted to the software.

The intelligent networking of signal towers creates a simple, cost-effective and retrofittable alternative to conventional complex MDC systems
Faults and unproductive times can be detected, analysed and documented more quickly
Response times are shortened, downtimes are avoided and productivity is increased

What a clever and simple principle: a signal light that is supplemented with a corresponding module and then immediately sends all the data from the machine to a central database. I was immediately convinced.

Bas van Nes, Functional Safety Engineer at Flestic

MDE system solutions

Machine data acquisition (MDA) is an essential part of modern industrial manufacturing and production control. MDC systems involve collecting, processing and analysing operational data directly from machines and equipment in real time. This data provides valuable information about the condition, performance and efficiency of the machines and the entire production process.

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Result

Since the installation of the simple, radio-based and clever machine data acquisition system (MDA system for short), it is now clearly visible which machines are running and where malfunctions or breakdowns are occurring. This makes it possible to react immediately and without delay.

‘The system provides information about the process stability of the machines,’ says van Nes. Flestic is completely satisfied with the simple and clever MDC system from WERMA. It doesn't matter what type of machine, age or manufacturer - the WERMA MDC system only needs a WERMA signal tower as an interface.

When asked what happens next, van Nes replies: ‘We want to continue to analyse the data and refine our key figures. And, of course, equip every new machine with the WERMA system.’

Reliable key figures and analyses
Complete satisfaction with the system
Expansion planned

About the company

Flestic is a medium-sized company that produces customised flexible packaging solutions in Dronten, the Netherlands. The company started in 1979 in a farmer's barn with a few small customised models. Five years later, the barn became too small and they moved to their current location in Dronten. Flestic now has more than 40 extrusion blow moulding machines, 3 injection blow moulding machines, 26 injection moulding machines and 4 assembly machines.

The entire production facility in Dronten covers 7,000 square metres. With more than 80 employees, the company produces around 80 million blow-moulded products and 100 million injection-moulded products every year.