Company dedicated to the chemical resins business, with its main production plant located in Araucária/PR*. This plant has an annual production capacity of 263,000 tons of chemical resins and a melamine paper impregnation line with a capacity of 45 million m2/year. These products have various uses, including inputs for the production of wood panels, melamine papers, industrial adhesives and inputs for the automotive, pharmaceutical and cosmetics industries, among others.

* Purchased by Arauco do Brasil in April 2010

Challenge

Dynea Brazil sought a solution to better control the quality of raw materials acquired, reduce time spent on measurement records from various lab instruments, and facilitate access to results, since these need to accompany the product through production stages—and for that, a lot of paper had to circulate on the production line.

Dynea do Brasil was looking for an alternative that would make it easier to collect and send information from various laboratory instruments. They carried out various tests with long durations, such as sample humidity, and the data from the analysis always followed the sample around the factory floor, so there was a lot of paper with the information collected circulating around the production line.

Solution

The company chose InfinityQS, a smart manufacturing and quality control software. Dynea Brazil partnered with HarboR Informática Industrial to implement InfinityQS according to its specific needs: integrate lab instruments and make the data available in other plant areas, control the quality of base paper received from the supplier to ensure better final product results, and in the second phase, automatic production data collection to ensure more effective control. HarboR provided training to ensure the team involved was familiar with the features and configuration possibilities of the InfinityQS software.

“Starting from the premise that we can only control what we measure and only improve what we control, the InfinityQS tool fits the shop floor like a glove in terms of process and product management at a qualitative level. InfinityQS offers a viable solution for shop floor qualitative management from the operator to the plant manager. I see that InfinityQS is to engineering and production what SAP or TOTVS are to financial management,”

– Gerson Aldo de Souza, Quality & After‑Sales, Overlays Production

Results

Through the control charts and Cp and Cpk values, Dynea do Brasil was able to improve the quality of the raw materials received from the supplier, generating a significant improvement in the final product. Through the automatic collection of more than 40 parameters simultaneously, 5 minutes of work were saved on each sample.

With instrument integration, it was possible to separate internal measurements of the sample (right, center, and left), resulting in more effective control using average and within-range values.

The ease of retrieving specific information in InfinityQS greatly facilitated product traceability. It is possible to track production conditions and resin recipe/formulations used in non-conforming batches, making it easier to identify production issues.

• Annual savings of R$300,000 with better raw material quality control from suppliers
• Reduction of 50 operator hours per month by integrating the instruments directly with InfinityQS
• Prevention of lost production with automatic e-mail sending when a parameter is critical
• Agility in organizing and tracking information