Giebeler saves over €60,000: How data-driven transparency increases production efficiency

Making production efficient today means more than just ensuring stable processes. It is about uncovering hidden potential and utilising it economically. This is precisely the path taken by Giebeler GmbH from Eschenburg. The results are impressive: savings in the five-figure euro range.

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 is clear: Production efficiency is becoming a decisive competitive factor.

As in many injection moulding companies, Giebeler had large amounts of data at its disposal, but it was not being used consistently.

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

A lack of transparency costs valuable production time.

The key challenge was therefore: How can production be made so transparent that targeted, economically effective optimisations become possible?

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

The injection moulding machines were gradually connected, with production data acquired in real time and systematically evaluated. A key factor in this process is the software authentig which links machine data to specific production orders, thereby revealing connections that were previously hidden.

The difference is now clear in day-to-day operations:

• Clear visualisation of all relevant production metrics

• Structured shop floor meetings based on valid data

• Fast identification of standstills and quality deviations

• Targeted measures for process optimisation

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

Based on a 3-shift operation with 17 digitally connected injection moulding machines, this results in around 34,680 production hours. By consistently using data, Giebeler was able to increase productive hours by 8%.

The result: savings of €61,807.50 within just 17 weeks.

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

The savings achieved by Giebeler are a prime example of the potential of data-driven production:

• greater output with equal resources

• high plant availability

• reduced costs by means of fewer standstills and less waste

• high-quality, accurate decision-making

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

At the same time, a key aspect of modern production becomes clear: digitalisation only realises its full value when it is used consistently.

It is not the volume of data that determines success, but the ability to draw the right conclusions from it and derive appropriate measures to be taken.

With authentig from ENGEL, this becomes feasible:

• Data is knowledge.

• Knowledge is efficiency.

• And efficiency is a clearly measurable economic advantage.

Production efficiency is therefore no longer an abstract aim, but a concrete factor for success that makes all the difference in a competitive market.