Established in 2017 in the Jiangsu Province of China, Genzon Novel Materials (NM) is a part of the Genzon Group and specialises in the production of polyethylene terephthalate (PET) film. This is a high-performance, crystal clear thermoplastic film with high tensile strength, excellent dimensional stability, and low moisture absorption. It is commonly used for printing and lamination, aluminium plating, card protection, bronzing and waterproofing. Genzon NM has also invested heavily in R&D opportunities to develop new applications for PET.
The firm operates four German Donier lines and an additional domestic production line delivering an annual production capacity of 120,000 tons. They were keen to improve productivity and reduce waste to maximise the revenue from the fixed production capacity.
They were aware that waste and spare inventory were creating additional costs which could be avoided if the PET film could be trimmed more precisely to meet client requirements. They were also keen to minimise human involvement in the process to eliminate errors and faults in the trimming process. The production line machines were also requiring frequent knife changes. With more accurate and effective use of material, knife changes could also be reduced.
Finally, the solution needed to optimise the supply chain management system (SCM) and fully integrate with the firm’s Oracle E-business suite, (EBS).
During our initial discussions with the client, we were able to demonstrate that our X-Trim solution was able to address all the issues the client was keen to improve. X-Trim is a world-class trim optimisation tool that offers powerful, state-of-the-art multi-threaded algorithms to find the most efficient trim solutions.
Working together we were able to customise X-Trim to offer full Oracle EBS and SCM integration, and we implemented both our X-Trim Base Module and X-Trim Knife Change Minimisation option. These tools allow our system to maximise the production line output with careful pre-planning so that trimming is accurate and designed to make the best use of the material based on client orders.
Deploying X-Trim has delivered excellent results for Genzon NM, delivering a significant reduction in trim waste, allowing for increased throughput, reducing unused inventory, and increasing revenue. Trimming knives are replaced less frequently and there is considerably less wasted material.
Because X-Trim delivers automation and integrates with existing platforms the entire SCM system is more effective and there are fewer human interactions with the process, eliminating errors and faults. This has enabled the business to optimise their process and plan their demand and capacity strategies more effectively.
We are looking forward to reaping the benefits of Greycon’s system. Greycon has made the implementation process as easy as possible by integrating with our own Oracle ERP system. Greycon’s system will provide more economic benefits, improve business processes and save us more time for strategic thinking.