Neroli
Increases production by 28%
Personal care company improves its operational efficiency reducing downtime and managing to upscale its production to 1.8m units per month.
Our challenge
Neroli is a personal care company specialised in the production of customised solutions and home fragrances. With 18 years of operations, it uses 7 bottling lines to manufacture its products and ships internationally in Colombia, US and other countries in Latin America.
Due to its continuous growth, the company faces the need to improve its operational efficiency adopting process improvements methods and measuring its progress with OEE metrics. Capturing data manually becomes a headache, not only because of the increased costs and paperwork but also because of the lack of clarity, errors and delays. Neroli decides to automate the data capture for operational data in the plant floor.
Solution
Neroli starts using our solution to automatically capture OEE data from 7 production lines
With genial.io’s help, Neroli analyses the production process to identify the best points to capture data reusing machine sensors and additional sensors to minimise the errors in the measurements. Neroli also structures its processes around the machines so people and other external factors like hands, objects, re-inserting products into the production line do not contaminate the information with false data. This discipline has resulted in information with quality enabling them to make better decisions but also to automate the input into inventory systems automatically with data errors of less than 1% in product counts.
According to the company, our platform has become an information agent, so they decided to include more sensors to add data points and measure the use of material and waste automatically.
The results
Genial.io helps Neroli to visualise what that they did not have before: data and information. Having real time automatically captured data has enabled Neroli to anticipate problems and improve efficiency. When the company started measuring with the platform and discipline, they had a 56% OEE which they have managed to increase to over 70%. As a result, production has increased 28% from 1.4m to 1.8 million units a month using the same infrastructure and resources.
“Genial.io’s platform is simple, clean and easy to use”, according to Natalia Angel, production manager. In her words “I’ve worked with several platforms in the past and genial.io has surpassed the others in usability putting a special emphasis in the floor operator. When the tool is not designed for the operator, then the projects become too dependent on additional supervisors and support staff to help”
On a related topic, the team from genialio is always there to help. Francisco Rozo, digital transformation leader explains: “genialio’s ethos in customer service is impressive: the way they work is based on discipline: don’t waste time, the job is done”.
Neroli has successfully adopted the technology: operators use to register downtime justification, supervisors review issues in real time and at the end of the shift, managers analyse data and design strategies to improve processes. The platform has become part of the daily life for everyone in the plant.
Success stories
Reduces technical visits by 50%
Increases OEE by 15%
Increases efficiency by over 10%
Boosts productivity by 27%