Production Track Challenges
Improving Mold Change Processes
More Efficient Clay Drying
Water Management and Disposal in Production Lines
Challenge Overview
In water production lines, some filled plastic bottles are discarded from the production line due to issues such as damaged bottles, missing labels, or underfilled quantities, not because of water quality. Currently, this water is lost due to the absence of an effective and safe method for its recovery and reuse.
Challenge Description
Develop a smart and safe solution to extract water from rejected bottles while maintaining its quality and preventing contamination from microplastics or other impurities, allowing for water reuse and reduced material waste.
Criteria
Enhancing water sustainability within our operations.
Significantly diverting wastewater from the bottling rejection process.
Improving Mold Change Processes
Challenge Overview
Exa Factory is one of the leading manufacturers of ceramic and porcelain tiles Saudi Arabia. The factory operates 12 production lines, each with a daily capacity ranging between 3,000 and 6,000 m². A fundamental step in the process is mold changing when switching between tile sizes. However, this step is time consuming as it requires stopping the production lines in addition to conducting quality inspections, which ultimately reduces productivity.
Challenge Description
Develop an effective solution that minimizes mold changeover time in tile production lines, to improve efficiency, reduce downtime, and increase the factory's ability to meet changing market demands.
Criteria
Reduction of changeover time
Compliance with quality and safety standards
Mold flexibility across various types and production scales
More Efficient Clay Drying
Challenge Overview
Pottery is a traditional craft practiced across various regions of Saudi Arabia, which represents an integral part of the local cultural identity. However, the clay drying process faces a challenge, particularly in cold conditions, where drying is slow, affecting production capacity and increases the risk of damage to the product.
Challenge Description
Develop a solution or mechanism that accelerates the clay drying process in pottery while preserving quality and preventing cracking or breakage during or after drying.
Criteria
Ensure the product does not crack or break during drying or firing.
Maintain high quality coloring of the product.
Keep production costs low.