Context
ISOSPA was founded in Florence in 1984. It produces and transforms expanded polystyrene (EPS) for packaging, construction and scenography. Packaging in particular has become a strategic and demanding market.
Challenge
- Manual supervision. Production was supervised manually, so errors and delays reached customer delivery dates.
- Limited visibility. Operators, machines and work orders shared little real-time information, so productivity issues were found late.
- Data for decisions. Management needed reliable data to reduce scrap and operating costs.
Architecture
- Metalya Core:
- plant and product master data
- work orders, with tasks and documents dispatched electronically
- web-based operator workstations
- Metalya Connect:
- production data collected automatically from the machines
- an application interface to business systems
- Analytics: live reporting in the Grafana-based analytics layer.
- Metalya APS: planning and scheduling on the same production data.
Implementation
ISOSPA connected its machines first. It then moved shop-floor work to Metalya’s production management: work orders, documents and declarations became digital, and paper left the floor. Planning came next, on the same orders, resources and progress.
Result
- Machines, operators and devices share a real-time view of production status.
- Scrap, downtime, work times, setups and material consumption are monitored as they happen.
- Equipment effectiveness is analysed from recorded data instead of estimates.
- Planning is more balanced, with shorter lead times.
Evidence
The results above are qualitative, as described in ISOSPA’s published case study. No figures are claimed.