Case Study: PLZ Corp achieves improved production control, increased sales and up to 20% faster line speeds with Hertzler Systems Inc.

PLZ Aeroscience Improves Production Control, Increases Sales

PLZ Corp, North America’s largest custom aerosol manufacturer, was struggling to scale after rapid growth and acquisitions because legacy paper-based quality systems hid problems on the shop floor and consumed staff time. Faced with rising costs, customer complaints and conflicting corporate goals to cut headcount while improving quality and productivity, PLZ sought a consolidated, real-time data solution and evaluated options before selecting Hertzler Systems Inc and its GainSeeker Suite manufacturing intelligence platform.

Hertzler Systems Inc implemented a custom-configured GainSeeker Suite deployment across production and lab lines, automating data collection and real-time analytics so operators see results immediately. The solution reduced variation (Cpk improved from 0.66 to 1.63), cut material costs and product holds, halved the quality department, and increased line speeds by up to 20%. PLZ now manages ~100,000 data points/month from 11 lines, generates analyses in minutes instead of ~100 man-hours, and reports higher production, lower inventory and increased sales.

PLZ Corp

Douglas Niemeyer

Corporate Quality Engineer