By: Kelin Regina Wirth – Journalist/Press Office
In 2001, Rotoline manufactured and sold its first Shuttle model machine. In the same year, Tecnotri acquired the same machine model to start its operations in the rotomolding industry. Over the past 21 years, Tecnotri has acquired other machines of the same ShuttleShuttle Machinemodel and recently, a Carrossel machine became part of the manufacturing park in Vila Maria, Rio Grande do Sul, Brasil.
The new model started to be used for the manufacturing of the new OEM line, products specially manufactured for the automotive industry. The initial plan was to manufacture 65 pieces per mold, dedicating 88 hours weekly just for this line. However, expectations were exceeded, and it was possible to produce 50 pieces per mold, operating only 44 hours per week. In other words, 77% of the initial projected capacity was achieved in half the planned time.
The Production Manager of the OEM Line, Cristóvão Longo, highlights that this was possible with the Carrossel machine in operation 'because it is new within Tecnotri, (we used to work only with Shuttle), [the new machine] contributed greatly to improving the numbers, in relation to the expectations of initial estimated productivity. Due to the oven capacity and its efficiency, as well as the improved cooling times (compared to Shuttle), we are working with the machine only in one shift and achieving maximum production.'
The Carrossel model machine is ideal for this type of production: sequential and in large quantities, as it presents higher productivity compared to other models. In Tecnotri's case, significant differences in production cycle and capacity have been observed since the implementation of the Carrossel, a a six-minute difference in the total cycle. In other words, a time gain compared to the process carried out on Shuttle model machines.
More technology in operation
Although different models, Rotoline's Shuttle and Carrossel machines have some similarities: ease of operation, internally developed software, clear and operator-friendly information, etc. Therefore, the adaptation to the new machine model was smooth for the operators. 'The team dealt very well, even though it [the Carrossel machine] is more modern and has many more sensors and functions, it is very similar to the machines currently running in the factory, which made it much easier,' says Longo.
Tecnotri's new machine is also directly integrated into its MES (Manufacturing Execution System). In other words, machine data is shared in real-time with the management system that already existed within the company. The installation of RotoAPI4.0 (Rotoline Application Programming Interface) made this possible. An API developed by Rotoline responsible for providing machine monitoring data to customers. This API collected the performance and productivity data presented earlier.
Another significant difference between machine models is that, in the Shuttle model, a cart can be left in the oven while another waits outside for cooling and load/unload. In the Carrossel model, carts are independent but operate sequentially. When starting operations with the new machine model, Tecnotri's operators, with their expertise and experience in rotomolding, realized that part extraction could be a bottleneck in machine operation. Longo comments that this is closely linked to productivity data 'It was noticed that part extraction can be a bottleneck. The faster the extraction and loading of molds, the higher the productivity. So if the extraction and loading of the mold takes longer, the carts will be waiting at other workstations.'
Proper training and efficient technical support
Another factor that contributed to ease of operation was the training offered by Rotoline to Tecnotri’s team. Cristóvão emphasizes the importance of good training and technical support, which made all the difference for operators 'Technicians teach in practice how to operate. Another thing that helped a lot in the transition was the availability of Rotoline support; any doubts the operators had, we had the answers promptly.'
Tecnotri's successful journey in the rotomolding industry, from acquiring the first Shuttle model machine from Rotoline in 2001 to implementing the Carrossel model, is proof of the efficiency and innovation that permeate the partnership between the two companies. Over the years, Tecnotri has not only increased its production capacity but also raised standards of quality and performance, resulting in impressive achievements.
The transition to the Carrossel machine represented a significant milestone. Not only due to the modernity and efficiency of the equipment but also due to the expertise and adaptation of Tecnotri's operators.
The partnership between Rotoline and Tecnotri not only encouraged growth and innovation in the rotomolding industry but also established a standard of excellence and collaboration that continues to inspire in the pursuit of maximum efficiency and quality.
