A global leader in blown plastic bottle development, sales and manufacturing, Graham Packaging operates in 17 countries, focusing on delivering solutions and adding value to packaging to meet customer needs worldwide. In Brazil, they operate plants focused on producing packaging for automotive and food industries.
In yogurt packaging production, bottle wall weight and thickness are key process variables essential for meeting customer expectations. Analyses are conducted hourly, and results were logged on paper forms, making monitoring and traceability slow and laborious. Process variation and sampling per shift had to be tracked manually, requiring eight hours just to transfer paper data into Microsoft Excel. Graham Packaging Brazil sought to implement a system to optimize inspection data collection and logging, reduce entry errors, generate real-time charts and reports, comply with equipment control standards, and automate quality certificates for clients.
InfinityQS was chosen as the quality management solution. Bottle measurements are sent directly from instruments to the software and displayed instantly in monitoring charts. Shift-based reports were configured to show inspection counts and capability indices in real time. Beyond quality inspections, instrument checks and component traceability were also recorded in InfinityQS. Graham Packaging Brazil leveraged HarboR Informática Industrial expertise to deploy the system in its quality lab and on four blow-molding lines, as well as train staff in software use and best maintenance practices for a simple and intuitive system. HarboR also customized client quality certificates with auto-filled data from InfinityQS.
“With InfinityQS, data entry was automated to ensure reliability, drastically reducing operator analysis time from 20 to just 5 minutes for hourly analyses. Previously, a full day was required to organize paper-based data into Excel and analyze information; now it’s completed in just 5 minutes per shift.”
-Edson Rogante, Analista da Qualidade da planta de Poços de Caldas
Typing errors were eliminated through automatic data submission to the software, and sampling times were reduced.
Management reports and dashboards generated instantly with clear interpretation are used to track process variability due to unintended interference or lack of standardization across shifts. With batch genealogy reports, traceability became much faster. They achieved compliance with ISO 9001:2008* through measurement equipment control logged in InfinityQS, providing: Quality Management visibility to monitor equipment variation over time; Reliable results for audit presentations.
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