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Case study 1: Cutting Excess Giveaway by 50% with Real-Time Weigher Management
Case study 1: Cutting Excess Giveaway by 50% with Real-Time Weigher Management
Case study 1: Cutting Excess Giveaway by 50% with Real-Time Weigher Management
14,952 Kg monthly product loss reduced | Faster corrective action with real-time data | Multi-plant corporate-level insights
14,952 Kg monthly product loss reduced | Faster corrective action with real-time data | Multi-plant corporate-level insights
Introduction
Introduction
The client, a leading food packaging manufacturer, struggled with EGA losses of
over 14,952 Kg/month.
Lack of real-time data and accurate OEE tracking slowed corrective actions.
Manual reporting caused delayed responses and missed savings opportunities.
To address this,our Weigher Management Solution was deployed, driving digital
transformation on the shopfloor.
The client, a leading food packaging manufacturer, struggled with EGA losses of
over 14,952 Kg/month.
Lack of real-time data and accurate OEE tracking slowed corrective actions.
Manual reporting caused delayed responses and missed savings opportunities.
To address this,our Weigher Management Solution was deployed, driving digital
transformation on the shopfloor.
Customer Pain Points
Customer Pain Points
EGA Loss more than 1%.
Inaccurate OEE numbers
Lack of real time data.
Delayed response time
EGA Loss more than 1%.
Inaccurate OEE numbers
Lack of real time data.
Delayed response time
Definition
Definition
Excess Give Away(EGA) :
This is the extra product packed on average in each packet by the machine.
EGA = Average Packet Weight - Target Weight
EGA% = (EGA/Target Weight) * 100
For. e.g. if the target weight set on the machine for each packet is 15gm, and the
average packet weight is 16.5gm, the EGA will be equal to 1.5gm and EGA% would be
9.09%
Excess Give Away(EGA) :
This is the extra product packed on average in each packet by the machine.
EGA = Average Packet Weight - Target Weight
EGA% = (EGA/Target Weight) * 100
For. e.g. if the target weight set on the machine for each packet is 15gm, and the
average packet weight is 16.5gm, the EGA will be equal to 1.5gm and EGA% would be
9.09%
Solutions
Solutions
Realtime data collection from weighers.
Shopfloor screens for behaviour change management.
Android Tablets to record downtime reasons by operators.
Dashboard to analyse line wise, machine wise, SKU wise, and operatorwise OEE and EGA.
Corporate level data aggregation of multiple plants.
Customized android app, and telegram messages to reduce reaction time.
Realtime data collection from weighers.
Shopfloor screens for behaviour change management.
Android Tablets to record downtime reasons by operators.
Dashboard to analyse line wise, machine wise, SKU wise, and operatorwise OEE and EGA.
Corporate level data aggregation of multiple plants.
Customized android app, and telegram messages to reduce reaction time.
Results
Results
Our Weigher Management Solution collects precise data from multihead weighers
in food packaging factories, providing immediate insights to enhance efficiency
and reduce errors.
Our Weigher Management Solution collects precise data from multihead weighers
in food packaging factories, providing immediate insights to enhance efficiency
and reduce errors.
EGA Improvement Data
EGA Improvement Data
Benefits
Benefits
Automated MIS reporting via email
Improved data visibility.
Monitor multiple plants centrally from corporate.
Automated MIS reporting via email
Improved data visibility.
Monitor multiple plants centrally from corporate.
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