Mehler Engineered Products (EP), a leading manufacturer of technical textiles, demonstrates with impressive results how a machine data acquisition system leads to greater efficiency and precision in data-driven decisions in process optimization. This case study on shop floor digitalization proves how lengthy analyses can be transformed into lean and effective processes.

“We have not experienced such a fast and seamless IT project on our shop floor as the integration of the ENLYZE Manufacturing Data Platform.”

Frank Rosenkranz, Quality Manager

The Initial Situation: Time-Consuming Process Data Analyses in Excel

Mehler EP faced challenges known to many companies:

• Manual Data Processing: Local storage and manual analysis of process data led to delays.

• Regular Backlogs: The high time expenditure made it difficult to verify hypotheses and assumptions, complicating the identification and implementation of suitable process measures.

• Unclear Results: The lack of a data foundation did not allow for a clear derivation of the root cause of errors, leading to discussions regarding the effectiveness of corrective actions.

Days, not minutes, were required to achieve process optimizations.

Objective: Prevent Complaints During the Development Process, Speed and Precision in Process Analyses

The goal was to proactively identify potential causes of complaints, derive corrective actions, demonstrate their effectiveness, and systematically ensure product quality. The basis for this was easy and fast access to machine data, which enabled precise root cause analyses, as well as real-time monitoring to make quick adjustments.

The Solution: ENLYZE Reduces the Effort from Days to Minutes

The implementation of the ENLYZE Manufacturing Data Platform proceeded extremely smoothly: quickly and easily. Within 48 hours the system was integrated and delivered initial results.

Process Data in Real-Time: The Manufacturing Data Platform provides quality managers with centralized access to all relevant manufacturing information and process data.

Targeted Root Cause Analysis: With the ENLYZE app, relevant process analyses are available in real-time. One example:

Issues in the manufacturing process, such as temperature overshoots, are visualized and analyzed in the ENLYZE app with just a few clicks. Problem causes are quickly identified and can be sustainably fixed through a process adjustment.

“I just have to enter the order in the search, select the relevant process parameters, and can start the analysis right away. The insights are a game changer, especially for the technical causes.”

Frank Rosenkranz, Quality Manager

Concrete Results: Reducing Costs, Improving Processes, and Saving Time

With the ENLYZE Manufacturing Data Platform, Mehler EP sets new standards:

• Time Savings: Analyses no longer take days, but minutes.

• Cost Reduction and Increased Customer Satisfaction through systematic and sustainable elimination of potential causes of complaints.

• Effective Implementation and Communication of Process Adjustments to permanently prevent complaints.

• Deepened Process Understanding and increased expertise.

  
  

“The entire process is faster, safer, and more comfortable. This allows us to systematically and sustainably eliminate potential causes of complaints, saving us time and costs, while ensuring high customer satisfaction.”

Frank Rosenkranz, Quality Manager

The Key to Success: Proven Digitalization Methods

Digitalization with ENLYZE was a significant advancement for Mehler EP. Without a large and lengthy IT project, transparency, efficiency, and sustainable prevention of complaints were achieved.

A key point is that the implementation was quick, and the machine data is now collected automatically. This eliminates the tedious manual data collection and the comparison of information from various systems. Instead, Mehler EP can access the required data and analyses in the ENLYZE app with just a few clicks. This user-friendliness makes everyday work significantly easier and enables faster data-driven decisions.