With production surpassing 7,500 units of control and signaling buttons per day, WEG’s packing machines faced challenges that directly affected operational efficiency, such as unexpected failures, quality inconsistencies, and high energy consumption. These issues increased costs, reduced machine reliability, and made production planning harder. Given this scenario, digitalizing the process became essential, and WEG Smart Machine (WSM) was chosen to transform the operation.

Before implementing WSM, monitoring the packing machines relied on manual tracking, requiring the team to spend several hours per week recording information in spreadsheets. The process was slow, prone to errors, and hindered fast decision-making. In addition, the lack of transparency and real-time data compromised collaboration between teams and corrective maintenance execution.

With WSM, the monitoring process became fully automated. The solution enables online collection of critical data, ensuring greater visibility of the operation and supporting faster, more assertive decisions. Eliminating downtime periods, combined with improved diagnostic and machine follow-up efficiency, resulted in a more stable and predictable operation.

The results are clear: monitoring the machine cycle enabled preventive replacement of the sealer’s space heater, avoiding unplanned downtime and reducing the need for corrective maintenance. Data analysis also identified energy waste while the machine was idle, allowing setup adjustments and lowering consumption. Additionally, tracking parameters such as power and resistance improved sealing quality, ensuring traceability and consistency across produced batches.

With these improvements, the operation achieved potential gains such as a 20% reduction in unplanned downtime, 14% energy savings, and an 8% improvement in quality. These indicators reinforce the impact of digitalization and show how WEG Smart Machine supports a more efficient, safe, and market-aligned industrial operation.