GS Gomma S.r.l.
GS Gomma specializes in molding technical rubber components, operating both as a contract manufacturer and a producer of proprietary solutions for highly demanding sectors such as automotive, hydraulics, and medical devices. Leveraging a unique blend of advanced technologies, artisanal know-how, and a heterogeneous fleet of presses, the enterprise initiated a comprehensive digital transformation to enforce strict operational efficiency and rigorous cost control.
Elevated production efficiency across the entire press fleet.
Drastic reduction in operational scrap and costly rework.
Formidable surge in operating margin per work order.
Neutralization of unplanned machine downtime.
Uncompromising increase in delivery punctuality.
The Challenge
GS Gomma previously governed its production using paper-based modules, manually compiled by operators at every single stage: from compound mixing and molding to cryogenic deflashing and final packaging.
This archaic methodology generated severe delays, frequent data entry errors, and a total absence of real-time operational visibility.
The 13 presses on the shop floor—only partially equipped for Industry 4.0 paradigms—prevented the automated monitoring of machine statuses, alarms, cycle times, and output volumes.
Industrial cost accounting was executed ex-post using fragmented, inaccurate Excel spreadsheets: true intelligence regarding indirect costs, operational inefficiencies, setup times, and labor utilization was entirely missing. The enterprise urgently required a transparent, continuously updated vision of its industrial costs for every single item and work order.
The Industrial Cloud Solution
Industrial Cloud engineered a complete digital transformation for GS Gomma through the deployment of the AgileFactory MES, meticulously sculpting the architecture around the enterprise’s true operational demands.
The deployment encompassed the total digitalization of all manufacturing phases—from raw compound procurement to cryogenic deflashing and packaging—guaranteeing continuous traceability and unyielding, real-time data reliability.
The fleet of 13 presses, a complex mix of Industry 4.0-ready machines and obsolete legacy equipment, was seamlessly interconnected utilizing standard protocols alongside specialized I/O modules. This secured the automated harvesting of machine statuses, cycle times, alarms, and overall productivity metrics without requiring the replacement of existing hardware.
Today, production orders are transmitted digitally to operators via interactive touchscreen terminals. These interfaces concurrently enable the surgical recording of cycle times and the immediate flagging of operational anomalies.
Empowered by the seamless integration with the MES industrial cost accounting module, GS Gomma now calculates the absolute total cost of every work order with uncompromising precision, factoring in raw materials, direct labor, indirect overhead, setup times, and scrap rates.
This profound transformation has empowered the enterprise to seize total command over its costs, eradicate operational waste, and significantly amplify press productivity..
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The Results
- > 1 Million molding cycles fully digitalized and tracked every month.
- +25% average productivity surge across the entire press fleet.
- -40% reduction in rework and scrap, driven by integrated quality control protocols.
- +18% increase in work order margins, unlocked by surgical, real-time cost calculation.
- > 500 hours recovered annually by permanently eliminating manual data entry.
