How Giebeler Saves Over $70k with Data-Driven Transparency and Increased Production Efficiency

Making production efficient today means more than just ensuring stable processes. It’s about uncovering hidden potential and using it economically. This is exactly the path Giebeler GmbH from Eschenburg has taken. The results are impressive: over $70K in savings.

As a medium-sized plastics processor with its own toolmaking department, Giebeler covers the entire value chain – from design to the finished component. In a dynamic market environment, one thing was clear: Production efficiency is becoming a decisive competitive factor.

Like many injection molding companies, Giebeler had large amounts of data available, but it was not used consistently.

Decisions were often based on experience instead of reliable key performance indicators. Downtime, rejects, or inefficient processes could be suspected, but not clearly quantified.

A lack of transparency costs valuable production time.

The central challenge was therefore: How can production be made transparent enough to enable targeted, economically effective optimization?

With the introduction of ENGEL’s authentig MES, Giebeler has taken the decisive step and is transitioning from reactive to data-driven production.

The injection molding machines were gradually networked and production data was acquired in real time and systematically evaluated. A key factor in this process is the authentig software, which links machine data to specific production orders, reveals connections that were previously hidden.

The difference is clearly evident in day-to-day operations:

• clear visualization of all relevant production metrics

• structured shop floor meetings based on valid data

• fast identification of downtime and quality deviations

• targeted measures for process optimization

Production is thus not only monitored, but also made transparent and actively controlled.

Based on three-shift operation with 17 networked injection molding machines, this equals approximately 34,680 production hours. By consistently using data, Giebeler was able to increase productive hours by 8%.

The result: savings of approximately $70,800 within only 17 weeks.

The decisive added value is evident where it matters most for companies: in the result. Production efficiency becomes a measurable economic lever.

The savings achieved at Giebeler are an example of the potential of data-driven production:

• more output by using the same resources

• high equipment availability

• reduced costs through less downtime and fewer rejects

• high-quality decision-making

What Giebeler achieved goes beyond short-term savings. The transparency and efficiency gained in production lay the foundation for a continuous improvement. Production becomes more predictable, stable, and economically optimized – day after day.

At the same time, a central aspect of modern production becomes clear: digitalization only realizes its full value when it is used consistently.

It is not the quantity of data that determines success, but the ability to draw the right conclusions from it and take appropriate action.

With authentig from ENGEL, exactly that is possible:

• Data becomes knowledge.

• Knowledge creates efficiency.

• And efficiency becomes a clearly measurable economic advantage.

Production efficiency is therefore no longer an abstract aim, but a concrete success factor that sets companies apart from the competition.