Interview with DUO PLAST AG

Since 2020, we have been working with the film manufacturer DUO PLAST AG and supporting the company in digitizing its manufacturing processes.

DUO PLAST AG has received a number of awards in recent years, including the German Packaging Award and the WorldStar Award. We at ENLYZE are therefore particularly pleased to support DUO PLAST AG and to be able to call this innovative company our customer.

Recently we sat down with Alexander Kaunath, Operations Manager of DUO PLAST AG, and with Detlef Kaase, COO of DUO PLAST AG, and talked about our cooperation.

Why did you decide to work with ENLYZE?

Detlef Kaase:

We are constantly looking for ways to improve our production processes, manufacture more productively and bring new innovations to the market. When researching industry trends, we have therefore been interested in the area of “Industry 4.0” for quite some time.

Alexander Kaunath:

Already during our first telephone conversation, I had told you that we have a very diverse machine park. To this, you said: “Don’t worry, we’ll manage”.

Even though I was skeptical at first, I was still very curious. In particular, however, I also had the impression that your solution would really help us to reach our goals. In all discussions and also in our current cooperation, we feel very well supported by you. Again and again, the impression is confirmed that your main motivation is for your solution to create a positive impact at DUO PLAST.

Detlef Kaase:

Indeed, we very much appreciate this cooperation in the spirit of partnership.

A fast and smooth integration process is very important to us. How did you perceive this?

Alexander Kaunath:

After we decided for piloting the ENLYZE solution, your integration team came by for half a day and prepared everything to connect your Sparks to our pilot machines.

The effort on our part was relatively low. Our maintenance and IT departments were involved for a few hours in the beginning until we implemented the firewall rules and got the internet connection up and running. But that was it.

Detlef Kaase:

Yes, especially in our second rollout stage, the process was particularly smooth and fast. After a few hours on-site, you left again. A few days later, all the machines were already online in the app.

Alexander Kaunath:

Even though I was skeptical at first, the results showed me that everything went smoothly in the end. I especially like that our most recent extensions to the machines were able to be integrated into the ENLYZE platform as well. With our visual inspection systems connected, we can now better analyze the measurements and correlate them with the process data. We were also able to connect additional individual controllers and sensors.

Above all, the process showed me that the ENLYZE system is really flexible. It is really well suited for our heterogeneous production environment.

Detlef Kaase:

For us, it is a huge advantage that we can remain flexible with your solution. Thus we can independently select the best systems and components we need. For us, this means that we don’t have to think too much about expanding or upgrading our machinery, because so many systems are compatible with the ENLYZE platform. This makes machine connectivity and data analysis a lot easier.

What has changed for you as a result of using the ENLYZE platform?

Alexander Kaunath:

Since we started using the ENLYZE platform, the transparency and understanding of our production processes have improved. Above all, we have a complete overview of our production processes thanks to the automated recording. Thus, no information is lost anymore.

Previously, it was quite time-consuming to track the influences on our processes. In order to track and analyze incidents or test runs, we had to invest a lot of time and manually read the measured values from the HMIs or search and combine various paper printouts of the machines from folders. Now, this is no longer necessary because everything happens automatically in the background, data is saved, and is easily accessible via the ENLYZE app.

Detlef Kaase:

This also helps our development department. The traceability of events in our production takes our process understanding to a new level. All the information can be accessed very easily via the search function and we can jump straight into the analysis. This is of great value for us when developing new products on the one hand and to further improve the production efficiency of existing products on the other hand.

Alexander Kaunath:

The ENLYZE app also helps me in day-to-day operations. It happens from time to time that something doesn’t go according to plan and we can’t explain it at first. For example, when certain production orders have higher scrap rates. Up until now, there was always a big discussion – everyone involved got together and discussed what the cause could have been and what we could do better in the future. Whatever we came up with in these discussions, the proposed solutions weren’t always sensible since assumptions and hypotheses were involved.

Today, when we encounter a problem like this, we take a look at the app and can quickly understand what has happened and confirm or refute assumptions. This enables us to come up with better solutions more quickly. Taken together, this allows us to gradually increase manufacturing productivity.

If you had to summarize ENLYZE briefly, what would you say?

Alexander Kaunath:

With the ENLYZE platform, we now have an easy-to-use tool for continuously analyzing and improving our production: thanks to the technology, we can monitor and control our production much more precisely, respond to changes early on, and optimize it step by step. With the integration, we’re completely up to date and are positive that we can gain further competitive advantages in the future.

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