The blow and injection molding plastics industry saw healthy growth between 2017 and 2018. However, despite the positive initial numbers, the economic crisis caused that performance to shrink.
Nevertheless, losses can be reduced with processes and tools that organize and improve production management and control. In this post, learn how the production planning and control (PCP) method can help.
The importance of production control in the plastics industry
In 2017, the newspaper Valor Econômico published an article highlighting the importance of the plastics industry in Brazil. According to the data collected, production reached an impressive 6.13 million tons.
The optimism repeated itself in 2018, when this industrial segment projected 3% growth. But it slowed down, rising only 0.8% in 2019, a number well below expectations.
At the end of last year, the market was once again projecting timid growth for the industry in 2020. And, with the economic crisis driven by the Covid-19 pandemic, the sector suffered a loss of -5%.
To try to work around the financial loss, this activity needs to bring in technological means and integrated tools that can contribute to the development of the business, as is the case with PCP.
This process aims to help the plastics company manager gain more effective control over ongoing production runs. With this more automated monitoring, it is possible to prevent capital drain and merchandise waste.
To make this possible, it is necessary to analyze the main management processes present in this production. They are:
1. Production planning
Managing processes in a factory is quite a complicated task, one that demands an enormous amount of time from the professional in charge. Therefore, solutions aimed at simplifying this work should be taken into account. One of the most effective outcomes for this planning is investing in an ERP system. This software aims to automate data and provide resource availability, delivering the possibility of viable production.
The use of an ERP is also directly linked to the quality of PCP. This way, the manager achieves a reduction in raw material losses at this early stage.
2. Tooling control
Having an ERP capable of managing tooling is essential for the plastics industry to be more efficient when checking the parts and molds needed for production.
With the right solution, the manager can identify which materials are indispensable to the company's production processes and invest more in these tools. This control is also important to prevent these items from developing problems and requiring longer maintenance time, which will certainly impact the production line.
The benefits of PCP in the blow and injection molding plastics industry
Production planning and control has been present in the industrial segment since the sector's first revolution. In the old days, workers and managers performed this control with the famous "eyeball method." Today it comes online and fully integrated into the work.
Adopting a PCP system in a plastics company is an important step toward achieving work integration. This way, employees can deliver production on time and managers save on materials.
PCP also represents the possibility for the company to earn more and avoid taking on debt from lost production. Learn about the other benefits of this mechanism:
1. Process integration
As a way of reducing raw material losses, process integration supports the manager with important data. For example, the sales department needs to be aware of what is happening in inventory, with access to production data.
The ability to automate this contact means the company no longer wastes time and even avoids missing demand deadlines for important customers.
2. Reduced raw material losses
We saw earlier that the lack of a technology system in blow and injection molding plastics companies is one of the major causes of material loss. By using PCP, employees can correctly measure the quantities needed for production.
As a result, production lines are staffed with people better suited to handle the processes, and the company avoids greater financial drain.
3. Organization and logistics
A PCP system integrated with an ERP for the plastics industry segment makes production more efficient. However, for this benefit to be truly felt, resources need to be better organized.
This organization must therefore span every area of the company, enabling the ERP to collect information from sales, finance, production, materials, services, costs, quality control, and even human resources.
With the broad ability to have all information in a single place, PCP built together with the ERP guarantees a drastic change in the company's logistics. A new work routine emerges, adaptable to different situations.
4. Better use of capacity
With the automation of these processes, the manager also has the opportunity to better understand the company's production capacity. Idle machinery can generate losses and should have its use reconsidered. Improving the use of the company's total capacity also aids decision-making when replacing machinery or retiring several machines.
If your company has production problems and spends a good amount of time wasting resources, it may be time to rethink how this information is being analyzed.
Like other important industrial segments in Brazil, we understand that the blow and injection molding plastics industry plays a leading role, and its production needs to remain competitive. End-consumer gains are also company gains.
Learn more about Useall solutions for industries and find out the best way to automate your production control processes by requesting a demo on our website.
Originally published in Portuguese at useall.com.br.