How does Simoldes monitor the operations of 7 factories in real time?

Testimony

"We must have access to data in a fast way to be able to make quick and reliable decisions, and proGrow is aimed at exactly this."

Domingos Pinto
Simoldes CEO

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Client

Simoldes Plásticos is one of the divisions of Simoldes Group that has 9 factories spread across Portugal, France, Poland, Czech Republic, Brazil and Morocco. Simoldes Plásticos produces plastic components for the automotive sector, supplying OEMs like Renault, Volkswagen, Stellantis, GM, Porsche, among others.

• 610M€ in 2019;
• 95% Export;
• 5200 Employees.

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Challenge

With a universe of nearly 300 injection machines, the production was managed based on manual records filled by employees in each position and with visual tables indicators filled by supervisors. It was a complex, heavy and time-consuming process inanalysis of the created history.

The project had three main objectives:

• Increase the performance of the Simoldes by reducing administrative tasks with no added value;
• Increase Indicators performance, such as the OEE, with rapid response to performance problems highlighted in the information provided;
• Digitizing Continuous Improvement Processes, promoting a share of knowledge.

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Solution

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Shopfloor

proGrow is integrated with the ERP and with all the injection machines from 7 factories. It is possible to manage the entire Simoldes universe in a single view and the platform has specific alerts and escalation on situations that are bellow the target. All downtime, stops and micro stops, are categorized in the proGrow, automatically alerting the respective departments.

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Automatic Reporting

Automatic reports configured to follow all performance evaluation meetings, from a daily operational meeting to a monthly management meeting.

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Workflow Management

Work instructions and SMED processes were digitized, as well as the management and monitoring of continuous improvement projects.

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Results

The return on investment was clear from the beginning of the project. The time reduction in the administrative work was sufficient to recover in short term the proGrow platform investment. Potential medium-term gains show the real profitability of the platform.

• 463 K€/year - Potential gains in administrative work reduction

• 507 K€/year - Potential gains in Operational Performance

• 567 K€/year - Potential gains in Continuous Improvement Department
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