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Sistema Plastics Accelerates Their Growth with MES and ERP

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Sistema Plastics Enjoys Accelerated Growth with ERP and MES Solutions

Sistema is an iconic New Zealand-based company that manufactures, markets, and distributes stackable food-safe plastic kitchen storage containers. From humble beginnings in 1982, the company has grown to become a world-leading brand that exports to more than 100 countries worldwide and counts its customers in the millions. A recognized innovator in the field of plastics manufacturing, the company operates from a new state-of-the-art production facility in Auckland that’s packed with automation and robotics technologies.

The Challenge

To ensure its products remain internationally competitive, Sistema wants to maximize production output and quality in the most cost-effective way possible. “Based in New Zealand, we’re a long way away from many global customers, so optimizing manufacturing performance is mission critical for offsetting the impact of high logistics costs on our business,” explained Greg Heeley, chief technical officer at
Sistema Plastics.

Ten years ago, the company implemented EpicorAdvanced MES to manage its production and assembly processes. Handling everything from scheduling to the monitoring of 10 assembly lines, Epicor Advanced MES collects and analyzes data directly from equipment and operators on the shop floor to provide an up-to-the-minute view of machine and production availability

“Without Advanced MES, our shop floor wouldn’t know what to make or when to make it,” explained Heeley. “Using the system has enabled us to run more machines with the same number of staff and move from a 24/7 to a 24/5 shift pattern without compromising output.” “Integrating Epicor ERP with Advanced MES would allow us to connect our planning, scheduling, and quality data with shop floor realities in one unified system,” he continued. “This would enable us to work smarter and further optimize operational efficiency.” 

Benefits Enjoyed after Implementation

  • Integration of ERP and MES delivered seamless automation of multiple processes
  • Improved cycle times and reduced scrap and time
    between jobs
  • Boosted OEE by 10%
  • Reduced warehouse man hours by 50% with no loss
    in productivity

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