Microplásticos Improves Workers’ Learning Curve with Glartek’s Connected Worker Solution

Meet one of the largest producers of high-quality dimensional plastic components.

Founded in 1987

150M parts per year produced

500 workers across Portugal and Poland

The Challenge

Microplásticos struggled with inefficiencies in the assembly line due to a paper-based instruction system. This led to unclear operator guidelines, some setup errors, and extended training times for new workers, causing production delays and increased downtime. The absence of real-time monitoring further complicated problem-solving, highlighting the need for a more efficient, connected, and streamlined solution.

Solution

The solution focused in three key improvements: Digitalisation of operational processes and work instructions, digitalization of onboarding and training materials, and the implementation of a back office platform to help monitor processes and teams.

Results

40% reduction in training times

32% fewer setup errors

2x faster problem identification

15% less operational downtime

We have been able to reduce downtime and increase our productivity by mitigating errors, especially in set-up. At the same time, initial launches have  also become more controlled and stable.”

João Marques, Administrator at Microplásticos

Inefficient paper-based instructions, lack of real-time monitoring, and long learning curves.

Before implementing Glartek’s solution, Microplásticos faced several operational challenges. Their reliance on paper-based instructions led to unclear guidelines for operators, which increased the setup errors and slowed down production.

This system also resulted in longer learning curves for new workers. Additionally, without real-time monitoring, problem-solving was delayed, emphasising the need for a digital solution to streamline processes and speed up worker integration.

Digital work instruction and real-time monitoring for streamlined operations

Glartek’s solution digitized Microplásticos’ procedures, helping improve operational efficiency. A mobile application allowed workers to quickly access clear, step-by-step work instructions, significantly decreasing setup errors by 32% and reducing the training times of new workers by 40%.

Additionally, real-time monitoring enabled 2x faster identification and resolution of issues. This improved response times, reduced downtime in 15% and increased overall productivity, making their operations more efficient and streamlined.