1. Executive Summary
Prima Dental, a global leader in precision dental instruments, reached a turning point where physical scaling with more hardware no longer yielded sufficient returns. Implementing DataQI Insights shifted the focus from adding machines to improving productivity through digital precision. The result was an immediate 6% efficiency gain (equivalent to adding 10 new CNC machines) resulting in an annual value gain of $3,600,000.
2. Problem / Challenge
- Hardware Limitations: With 150+ machines, physical growth hit diminishing returns; focus needed to shift from 'more machines' to 'better productivity'.
- Manual Bottlenecks: Performance tracking was manual and slow, requiring operators to halt production for recording machine states.
- Data Latency: Reliance on stale data made real-time production agility impossible.
- Inefficient Quality Control: Traditional paper checklists lacked digital traceability and created inspection bottlenecks.
3. Goals & Success Metrics
Goals
- Automate data capture to replace manual logging.
- Integrate production data directly with existing ERP systems.
- Establish a single source of truth for real-time floor visibility.
Success Metrics
- $3,600,000 Annual Value Gained
- +6% Efficiency Uplift
4. Solution Details
We delivered a tailored implementation of the DataQI platform that integrated seamlessly with Prima’s ecosystem:
- Direct PLC Connectivity: Automated data capture replaced manual logs, capturing machine-specific error codes directly.
- ERP Integration: Work orders are automatically pulled from the ERP, streamlining production workflows.
- Digital Traceability: Paper checklists were replaced with digital audit trails for 100% batch traceability.
5. Results / Outcomes
- Output equivalent of 10 new CNC machines gained without additional hardware investment.
- Recovery of multiple full-time operator hours immediately through automated workflows.
- Immediate real-time visibility for both management and factory floor operators.
Client Testimonial
"By involving operators from the initial pilot, the technology was embraced as an enabler, not a monitor."