Transforming the global plastics industry with Nexus Connected Worker
Dr Asif Rana – President Nexus Connected Worker, Hexagon’s Manufacturing Intelligence division
Nexus Connected Worker
Historically, the company grappled with inefficient, paper-based systems that bogged down its operations. These antiquated processes led to cumbersome work order management, frequent human errors in data entry, and a glaring lack of real-time insight into operations. With more than 70 facilities scattered across North America, the disjointed data collection and management practices hindered not only productivity but also the strategic and timely decision-making capabilities essential for growth.
Enter Nexus Connected Worker – a beacon of digital transformation tailored for high-demand manufacturing environments. The company launched an ambitious revamp of its operational model, incorporating sensor hardware and the Nexus Connected Worker platform. Crucially, the integration of these components transformed the company’s stagnant, error-prone data landscape into a dynamic, insight-rich operational powerhouse.
The core of this transformation lies in strategically integrated sensor technology. These sensors, capable of real-time data integration, were deployed across production lines to monitor various metrics such as machine uptime, cycle counts, production KPIs, and overall equipment effectiveness (OEE). The real-time data gleaned from these sensors provide more than mere statistics; they offer a constant flow of actionable insights, encouraging immediate adjustments and predictive maintenance strategies that far outpace traditional reactive models.
Moreover, the Nexus Connected Worker digital workflows harness this sensor data to empower employees. Workers now have mobile access to real-time operational data, drastically reducing the time spent on administrative tasks like downtime tagging—from two hours per shift to less than ten minutes. This newfound efficiency has boosted productivity and significantly cut down the mean time to repair by empowering maintenance technicians with instant notifications and comprehensive machine health data.
The results speak for themselves. Since implementing Hexagon’s solutions, the company has seen a substantial reduction in scrap rates by 25% and has improved OEE scores significantly across its production lines, not to mention the immediate and real-time availability of this OEE data. The strategic integration of sensor technology with Nexus workflows has not only streamlined operations but also fostered a culture of proactive maintenance and efficiency.
This case study exemplifies how embracing modern technology and integrating comprehensive sensor systems with intelligent workflows can transform manufacturing operations. The journey of this global plastics company with Hexagon’s technology illustrates a successful marriage of innovation and practical application, setting a benchmark for others in the industry to follow.
For a deep dive into the details and transformative impact of the Nexus Connected Worker system, visit nexus.hexagon.com.