US based cosmetics manufacturer transforms their pre-weigh department processes through improved accuracies
A world-class leader in the development and production of high-quality make-up, skin care, hair care, bath & body care and over the counter products. This customer is an outsourcing partner to major global cosmetics brands as well as own-brands.
Key facts
The customer required a more robust process solution for their pre-weigh department and variations within the formulation of products required stringent levels of control. The customer had difficulties with the recording and accuracy of data as well as controlling the quantity of product. The Minebea Intec software ProRecipe XT® was the solution to overcome these challenges.
Application & Product
The pre-weigh department within the manufacturing facility required improved levels of precision, traceability and accountability. Raw materials are prepared within the pre-weigh area ready for use later in the manufacturing process
Products
Customer benefits
- A simple recipe process including scanners that ensured the correct use of ingredients that lead to a reduced failure rate, higher product quality and therefore improved profitability
- Improved weighing accuracy to ensure the correct amount of ingredients is used for each recipe and therefore improved product quality
- Improved accountability by use of dual signature approval for specific ingredients
- Integration with the customers ERP system
- Full traceability as they could document the process
- Improved efficiencies because of reduced wastage
The customer was experiencing processing difficulties within their pre-weigh department such as tracking who had processed orders, the recording of the correct raw products and quantities and whether handwritten information was correct. They also needed to ensure that the correct scales were being used to measure ingredients as well as ensuring employees were using and documenting the correct use of PPE within the process. The processes were time consuming and had the potential for errors as information was being captured using pen and paper making it difficult for others to read and challenging to control.
The combination of Minebea Intec products; ProRecipe XT®, Signums and Maxxis 5 was just the solution this global player needed. ProRecipe XT® had the capability to overcome many of the control and traceability issues; the customer instantly knew which user was signed in to the system and what was being worked on, they were able to ensure that the correct recipe was being formulated, the correct raw material was being used (by use of a scanner) and the correct quantities were being administered as they were weighed using the Minebea Intec bench scale Signum®. Where expensive raw materials were part of the recipe, they introduced dual signature controls so that employees were accountable within the process. The customer was also able to record ingredient weights and store batch records which were then transferred to their ERP system using the Minebea Intec Maxxis 5.
Ensuring employees were using the correct scales as detailed within the Standard Operating Procedures (SOP) as well as the correct use of Personal Protective Equipment (PPE) and that they had read the Materials Safety Data Sheet (MSDS) were all capabilities of the ProRecipe XT® software.
Within just a few days, the customer saw efficiencies within their processes such as reduced wastage and less time to record information manually, they had a clear overview of the entire pre-weigh process, the traceability they needed and the control to make changes as and when required.
Minebea Intec Sales Manager John Keane commented ”As soon as I heard about the difficulties the customer was facing, I knew that used simultaneously our software, scales and weight controller would deliver the results the customer required. In fact, they’ve gone beyond their expectations as the customer has also benefited from reduced wastage and therefore lower costs.”
Deputy Country Manager for North America, Sebastian Pedross said “The accuracy and level of control required within the manufacturing process of different cosmetics is on a very high level and comparable to the requirements of a Pharmaceutical manufacturing process amongst other industries we serve across the globe. We pride ourselves on our level of understanding the different weighing applications of each of our customers and their unique requirements. Having more than 150 years’ experience with several weighing applications in different industries enables us to add great value to our customers by improving their manufacturing processes so they return to work with us again and again.”
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