How to control waste in industry

Waste as an Industrial Challenge

Waste is one of the biggest barriers to competitiveness in the industrial sector. It encompasses not only discarded materials, but also misused energy, time and human resources.

According to National Confederation of Industry (CNI), the Brazilian industrial production faces efficiency and waste challenges, which directly impact the sector’s operational costs and sustainability. Thus, the adoption of advanced planning technologies, such as MES systems (Manufacturing Execution System) and APS (Advanced Planning and Scheduling), has been the way to reduce losses and optimize resources.

This article explores how specific tools, including DELMIA Ortems, SAP IBP, Infor Advanced Planning and Plex Smart Manufacturing, contribute to waste control and increased efficiency.

1. Diagnosis of Waste in Industry

According to the June 2024 Industrial Survey, published by CNI, the main causes of waste include:

Lack of production planning: Generates excessive inventories and material losses;
Low integration between departments: Fragmented decisions increase inefficiencies;
Insufficient use of real-time data: Makes it difficult to quickly identify operational problems;

In addition, sectors such as beverages, automotive and pharmaceuticals suffer especially from significant losses due to the perishability of products or the high complexity of the production process.

2. Waste Control Tools

2.1. DELMIA Ortems

Part of the Dassault Systèmes, DELMIA Ortems is recognized for its advanced planning capabilities such as scenario simulations and optimization of the supply chain. Among the main benefits, the following stand out:

Reduction of up to 30% in material waste;
Improvement in equipment usage by up to 20%.

2.2. SAP Integrated

O SAP IBP combines financial and operational planning on an integrated platform. Additionally, its predictive analysis helps predict demand, adjusting production to avoid unnecessary inventories.

Improves forecast accuracy by up to 15% and reduces inventory costs by up to 20% .

2.3. Infor Advanced Planning

This solution offered by Infor allows the execution of detailed planning for production and logistics. Based on artificial intelligence, it automatically adjusts schedules, avoiding bottlenecks.

Reduction in machine idle time and greater alignment between demand and production capacity.

2.4. Plex Smart Manufacturing

As a cloud solution offered by Rockwell Automation, Plex provides real-time visibility into your entire operation. For this reason, it is ideal for factories looking for flexibility and high adaptability.

Minimizes losses due to human error and reduces unplanned downtime.

3. Proven Strategies to Reduce Waste

3.1. from Factory

The adoption of IoT (Internet of Things) allows you to monitor processes in real time. Sensors installed in production lines help identify bottlenecks before they generate waste.

3.2. Scenario Simulations

Tools such as DELMIA Ortems and Infor Advanced Planning simulate different production configurations, allowing managers to choose the most efficient one.

3.3. Horizontal and Vertical Integration

For example, solutions such as SAP IBP promote integration between suppliers, factories and distributors, ensuring alignment of the entire chain.

3.4. Training and Qualification

The use of advanced technologies requires continuous training for operators and managers, ensuring that the tools are used to their maximum potential.

4. Economic and Environmental Impact

Companies that adopt waste control strategies report:

Reduction in operating costs by up to 25%;
Increased sustainability, with less disposal of industrial waste;
Improvement in the brand’s reputation with consumers and investors.

Necessary Evolution

Waste control is not just a matter of survival in a competitive global market. Tools like DELMIA Ortems, SAP IBP, Infor Advanced Planning, and Plex Smart Manufacturing offer practical, proven solutions to achieve this goal. However, success depends on an integrated strategy, which combines technology, training and continuous monitoring.

And, of course, these are not the only solutions for the industry. In this context, we have just a sample here, among other solutions that provide the necessary mechanisms to properly combat waste in the industry. Choosing the most appropriate tool that best adheres to your production process is certainly the most complex decision, for which Teclógica has more than 30 years and a highly qualified team, to help in this stage, and in following.

With a well-structured plan (and the ideal partner), waste reduction becomes not only viable, but inevitable. Let’s go chat?

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