Case Study: Ohio-based adhesives maker achieves 100% batch rework reduction with RoviSys automation modernization

Ohio-based adhesives maker eliminates batch rework in 6 months with RoviSys

An Ohio-based adhesives maker was facing significant challenges due to its reliance on heavily manual manufacturing processes, which caused approximately 90% of its batches to require re-work. With an aging workforce and obsolete control system infrastructure, the company needed to modernize its operations for consistent quality and growth. They partnered with RoviSys, a solution architect and systems integrator, to implement a modern control system and automated solutions.

RoviSys implemented a two-phased solution, first migrating legacy reactors to a modern control system with a supervisory batch system for standardization. The second phase automated manual processes by capturing tribal knowledge into repeatable algorithms. The results were immediate and dramatic; in the first six months, the plant did not have to rework a single batch, a 100% improvement that significantly increased throughput and decreased waste. This success transformed the company's culture and turned its CEO into an automation evangelist, securing funding for future digitalization efforts.