How O3ai transformed quality and maintenance results in a paper factory
In the fiercely competitive paper production industry, efficiency and quality control are paramount.
Obeikan Paper Industries, a major player producing 220,000 tons of paper and cardboard annually, faced some key challenges.
O3ai's smart factory solution turned things around, leading to improved efficiency in maintenance and quality management.
Challenges in Traditional Paper Manufacturing
Before O3ai, Obeikan grappled with two primary issues:
● quality control – monitoring was manual, periodic, and couldn't provide real-time feedback, leading to delayed responses to production faults.
● maintenance efficiency – bogged down by manual planning and inefficient work order management systems, which contributed to missed OEE targets.
O3ai's Technological Intervention
O3ai implemented its platform alongside IIoT tech across one of Obeikan's paper factories. It transformed key areas:
● Quality Management
O3ai automated and centralized quality control. This enabled real-time monitoring and faster response to quality issues. Overall, the number of rejects was reduced and overall product quality improved.
● Autonomous Maintenance
Maintenance workflows were streamlined and made more proactive with automated maintenance requests. This reduced the processing time of work orders.
Impressive Results in Quality Management & Maintenance
O3ai made a big impact on operations:
● 16% Reduction in NCRs
Real-time quality monitoring allowed for immediate corrections.
● 57% Reduction in Work Order Processing Time
Quicker responses to maintenance issues led to boosted uptime.
● 25% Cut in OEE Losses
Enhanced maintenance and quality control led to fewer production interruptions, directly boosting OEE scores.
The Future of Paper Production with O3ai
The potential of smart factory technology and AI is incredible. Automating and streamlining key processes and enabling real-time data analysis will transform any factory.
As industries worldwide push towards higher levels of sustainability and efficiency, embracing technologies like those offered by O3ai will help them get there.
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