A tyre-grade rubber plant grappled with inconsistent compound quality and slow troubleshooting. By embedding BatchViz from Symbiotic Automation into its SCADA, the mixing team visualised every parameter in seconds and cut off-spec rework by nearly one-third.
Challenges Faced
- Paper logs hid temperature and torque drifts, delaying corrective action.
- Operators lacked a single view of recipe, batch, and sensor trends.
- Manual reporting stole engineering hours and obscured continuous-improvement gains.
Implementation
The upgrade connected mixer PLCs to an SQL database feeding BatchViz dashboards. Engineers now replay torque, temperature, and energy curves per batch, overlay Golden-Batch profiles, and export one-click reports directly from the SCADA screen without halting production.
Key Implementations
- Real-time data broker streaming 1-second samples from mixers to database
- Web-based BatchViz dashboards embedded in existing SCADA HMI
- Overlay tool comparing live curves against operator-tagged Golden Batch baseline
- Automated PDF and CSV batch reports emailed to QA and production daily
Outcomes & Benefits
- 28 % faster root-cause analysis on off-spec lots
- 32 % reduction in scrap and rework within two months
- 100 % digital genealogy improves audit readiness and customer transparency
Future Scope
Next, the plant will deploy AI Anomaly Detection to flag curve deviations in real time and auto-select the next Golden Batch, creating a self-learning quality loop.