A photo of Polymerics using Synergy 2000 SPC software.
Polymerics using Zontec’s Synergy 2000 SPC software.

Polymerics specializes in custom mixing, dispersions and chemical blends. They custom mix both black and color rubber to customer specifications, requirements and expectations. They are an ISO 9001:2008 registered company committed to fulfilling customer needs.

“The product is easy to use, easy to setup. The day after we bought the product, we started putting in data.”

—Kim Marquis, Operations Manager for Polymerics

Polymerics had some manufacturing challenges that made them decide on a solution like the Synergy Statistical Process Control (SPC) software. “We realized we needed the ability to capture two devices into the same database,” said Kim Marquis, Operations Manager for Polymerics. “We recognized that our existing solution did not have the capability to handle it.”

“We selected Synergy because we can input data from multiple devices into the same database,” Marquis said. “With Synergy we could capture more data about our business. Email alerts for out-of-specification products were part of the deciding factor as well.” One of the benefits Marquis enjoyed about Synergy was its rapid implementation. “The product is easy to use, easy to setup,” said Marquis. “The day after we bought the product, we started putting in data.”

“Synergy is logical, straight forward and easy to use compared to the other software package we were using,” Marquis said. “The other software product was difficult to set up. Synergy is really easy: you can just view the data anywhere from the COM port or the hyper terminal.”

Polymerics has seen a number of improvements since implementing the Synergy SPC software. “We are able to mistake proof our process and are able to ensure the quality more than we did before. Synergy has saved on our customer complaints as well,” said Marquis. ”Now we are running the software in real-time, receiving notifications immediately if something is out-of-control. Operators can easily read the charts and address the issue from the floor. We can even decide how the screen will look. We didn’t have that flexibility before.”

“The traceability available in Synergy is great. For example, we can generate histograms for specific lot numbers, batch numbers, etc. I can easily chart that data as well,” Marquis said. “Synergy also enables me to keep track of my operators by making sure they run to the standard time. I can look at the schedule and look into the database. I can see how long it takes them to run something because the system date stamps everything. I can also schedule it differently if for some reason it starts to run longer than the standard time.”

Synergy has helped Polymerics with its customer satisfaction. “We’re more accurate in our data we provide to our customers. We can provide them lot numbers, batch numbers, operator numbers, and shift numbers, etc. The histograms we give them now have a lot more information on them.” said Marquis.

“I use Synergy mostly for the bag weight program for our materials. We pre-weigh powdered chemicals as to their weight specification. We send along a histogram with every Certificate of Analysis for every bag in each production run,” said Glen Peters, Lab Technician. “With Synergy, it is easy to find out-of-specification bags. I can look on the chart. It shows exactly which bag is out-of-specification.”

“What used to take a couple of days of work a week before using Synergy, now takes a push of a button,” said Peters. “Now we have real-time information as we are weighing the bags.”

Executive Summary

Customer

Polymerics specializes in custom mixing, dispersions and chemical blends. They custom mix both black and color rubber to customer specifications, requirements and expectations. They are an ISO 9001:2008 registered company committed to fulfilling customer needs.

Challenges

  • Capture two devices in the same database

Solution

  • Zontec’s Synergy 2000™

Results

  • Less than one day implementation
  • Saved 1 to 2 days of work a week

Quote

“I use Synergy mostly for the bag weight program for our materials. We pre-weigh powdered chemicals as to their weight specification. We send along a histogram with every Certificate of Analysis for every bag in each production run. With Synergy, it is easy to find out-of-specification bags. I can look on the chart. It shows exactly which bag is out-of-specification.”

—Glen Peters, Lab Technician for Polymerics

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