Customer Success – Smart Setup Process Management at Stölzle-Oberglas GmbH

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The Customer – 200 years of glass manufacturing

With the annual production of 3.25 billion glass products for packaging, Stölzle-Oberglas is one of the leading glass manufacturers in Europe. Stölzle has factories throughout Europe with the majority of production is primarily based in Austria and the Czech Republic. Tracing its roots to the year 1805 in the city of Bärnbach, Stölzle-Oberglas has refined the art of making glass for more than 200 years.

Today Stölzle-Oberglas is an industry leaders who drive and shape the future of glass manufacturing and is constantly innovating in all facets of production to ensure the highest quality in standards and processes. As the dawn of the digital era arises, Stölzle-Oberglas is partnering with Actyx in order to revolutionize age old practices and gain a strong foothold in the ever-evolving world of Industry 4.0.

The Problem – set-up times and parameter transparency

As Stölzle-Oberglas’ product portfolio grew with specialized lower quantity orders, common within the pharmaceutical, cosmetic and consumer packaging industry, pressure began to mount on the set-up costs and duration. In order to maintain profitable production on small batches, rapid and efficient product changes became a vital necessity.

The complexity inherent within material and production processing makes glass production exceedingly challenging. This is further impacted by environmental and material uncertainty which needs to be stringently controlled for successful production.

In order to be able to rapidly adjust to new setup parameters and automate control mechanisms, Stölzle turned to Actyx for a digital solution to aid their afflictions.

The Actyx Solution – a worker-focused setup assistance system

The challenge which Stölzle-Oberglas faced was to increase transparency and efficiency in the setup process to overcome issues in information availability and long setup times. In order to overcome this Actyx proposed to integrate real time setup process data on mobile factory devices providing employees with easily accessible, editable and comparable set-point parameters. These improvements were provided through the Actyx Manual Work Logging and Mobile Team Collaboration applications.

In addition to providing employees with real-time parameter data, the Actyx solution offers the ability to access historical production data at the click of a button as well as applying advanced analytics to increase transparency and consistently improve processes.

Actyx solutions are operated on the Actyx Ada Platform to ensure high security and availability on the edge. While mission critical and sensitive Ada components run on the edge, AWS  cloud services are used to deploy and remotely monitor Actyx applications, integrations and devices.  

Results and Outcomes – newfound flexibility and efficiency

Through its collaboration with Actyx, Stölzle has seen a decrease in machine setup times. The information regarding parameters are currently available to all relevant employees at the click of a button. This has solved many of the deficiencies that Stölzle-Oberglas faced and has led to a decrease in lead times due to the newfound flexibility and efficiency in the manufacturing process. Actyx combined state-of-the-art hardware and software technology such as AWS to help the customer increase operational transparency, improve process security and thus boost setup efficiency and flexibility.

Today Stölzle-Oberglas experiences the benefits which digitization can provide and remains at the forefront of the glass manufacturing industry. They continue to stand as an innovative role model and a satisfied Actyx customer.

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