How did Insulac start producing 6000 more units per day?

Client

‍Insulac – Produtos Lácteos Açoreanos, S.A., founded in 1992 in the Azores, is a leading company in the Portuguese dairy sector. With an industrial unit in São Miguel, the company produces cheeses and butter for the consumer market under the Valformoso brand and powdered milk and whey for the industrial sector under the Insulac brand.

The organization collaborates with around 220 local producers, processing 72 million liters of milk annually, resulting in 6,300 tons of cheese, 2,000 tons of powdered milk, 3,500 tons of dairy products, and 850 tons of butter. All its products are available throughout Portugal and exported to countries such as Canada, the United States, Morocco, Spain, and Belgium. With a strong commitment to quality and sustainability, Insulac stands out in the market as a leader in Azorean dairy products.

‍

‍Challenge

‍Before implementing a digital optimization solution, Insulac faced the challenge of obtaining a clear and detailed view of the performance of its sliced cheese production lines. The lack of structured data on stoppage frequency and causes made it difficult to accurately analyze operational efficiency, limiting the potential for continuous improvement and the identification of optimization opportunities.

This scenario led Insulac to seek a solution that would increase productivity, reduce waste, and improve the quality of its processes. The company aimed to accurately monitor production, quickly identify the causes of stoppages, and optimize machine utilization on the slicing and grating lines. Additionally, Insulac sought greater process visibility and improved communication between production sectors, fostering a more collaborative and data-driven approach.

The key performance indicators (KPIs) defined included production efficiency and machine availability, which were essential for reducing operational costs and ensuring a more effective workflow.

‍

Solution

‍The implementation of proGrow at Insulac was carried out with a careful approach to ensure a smooth adaptation to the already established processes. Initially, the team had to put in extra effort since employees were not accustomed to recording production data in a structured manner. proGrow introduced a digital solution that enabled the automation and precise recording of production activities. However, for this transition to be successful, it was essential for employees to incorporate tablet use into their daily workflow.

One challenge that arose during implementation was getting employees used to real-time digital logging. While the team had no major concerns, the initial adaptation period was crucial to ensure acceptance and familiarity with the platform.

With proper support and guided training, Insulac successfully integrated employees into using proGrow, facilitating the monitoring and analysis of operations.

‍

Results

‍After implementing proGrow, Insulac saw significant improvements, particularly in identifying the causes of stoppages and tracking machine status in real time. The digitalization of data on Line 2, later expanded to Lines 1 and 3, allowed the company to achieve its defined KPIs, with measurable improvements in production monitoring and operational efficiency.

One of the greatest benefits provided by proGrow was the agility in communication and response time. With the platform, employees no longer need to physically check the machines to verify production status, as this information is readily available on the machine's page in the system. This capability significantly improved process flexibility and enabled a faster, more informed reaction to any production issues.

Over the past seven months, the following increases in production indicators were recorded:

• Production efficiency (OEE): Increased by 44.4%
• Monthly production time: Increased by 99h17 (+50%), equivalent to approximately 3 additional hours per day
• Monthly production quantity: Increased by 206,702 units (+116%), translating to about 6,000 additional units per day

‍