Lone Star’s real-time predictive model for RIM mixing nozzles reduced clogging, scrap, and downtime, saving $450K annually and improving machine performance by 7%, with a ROI of under one month.
The Issue
A high-performance after-market automotive parts manufacturer was having trouble with 2-part Reaction Injection Molding (RIM).
Mixing nozzles were clogging, resulting in increased costs due to excessive downtime, scrap parts, and labor hours, while reducing machine utilization.
The Solution
Predictive Model Developed: Lone Star built a real-time predictive model to predict nozzle clogging so that operators are alerted when needed.
Root Cause Identified: Solution monitored other criteria, assisting with root cause determinations of quality impacts.
The Results
Significantly Reduced Nozzle Changes and Cost: Eliminated nozzle clogs and improved quality by reducing scrap.
Actionable Insights Delivered: The model led to insights that reduced raw material consumption by increasing purge delay times and by reducing purge volumes when needed.
Cost Savings of $450k – Annual cost savings were realized in excess of $450k annually in waste reduction.
Significant ROI Realized: 7% increase in machine performance. ROI < 1 month.
