50+ countries
Global use, local impact
9% cost reduction
Measured across 9 plants
40% faster audits
With automated traceability
< 3 months
From pilot to full rollout
Gulf Cans Industries, Abu Dhabi UAE
Gulf Cans Industries (GCI) UAE is a manufacturer and distributor of Aluminium Monobloc Cans for Cosmetics, Pharma Industries, Food & Drinks, Household, and Industrial Industries. GCI is located in Abu Dhabi, United Arab Emirates, and it is the first of its kind plant for manufacturing of Aluminium Aerosol Monobloc Cans and Bottles in the GCC region.
The plant has multiple High-Speed Lines fully automated with the latest technology and is equipped with 8 high-end colour printing machines and 40 Station Necking machines. GCI offers flexible options of shaping and decoration for aerosol packaging. The plant has the capacity to produce 150 million pieces per year. Currently it runs at 200 cans per minute.
Rapid Growth and High Ambitions
Gulf Cans Industries is originated in 2016 and experienced a rapid growth towards producing 120 million cans in 2022. After a few years of writing quality and process measurement results on paper-based records, and carrying out controls against specification limits, the GCI team decided to move forward and implement SPC. They selected Datalyzer SPC as the right tool and partner for this implementation.
The main objectives for GCI of the Datalyzer SPC implementation were to achieve stabilized and controlled
processes and to have the right tool and processes in place for continuous improvement.
Reduced Variation & Improved Quality
GCI started the implementation of DataLyzer SPC at one of their continuous processes; the extrusion of aluminium slugs. Main focus was to reduce and control the variation of the ‘basethickness’ which is critical in their process. And that was successful!
Everyone on the Shop Floor has access to the relevant process information to identify causes of variation and quickly get back in-control in case of an OOC situation. Many improvements resulted from operators focusing on control limits instead of customer specification limits. They focus on target values and eliminating special causes of variation using control limits visible in the Datalyzer screens and are improving quality.
Advanced analysis was available for the GCI team from day one of implementation. Type of Coating used and Thickness of Coating are analysed against Visual Inspection Quality Outputsusing Scattergram and Box and Whisker plots.
Operator Involvement and Daily Management
Operators at GCI are happy with the implementation of Datalyzer SPC. They were quickly up and running due to its ease of use and they like the real-time availability of all relevant information. It was critical for the implementation project to link gages to DataLyzer SPC automatically. Datalyzer reports are used during daily production meetings.
The process performance and production issues are discussed using, amongst others, the Notes Reports. Also, reports are created while finishing batches to report critical quality measurements and the quantity of measurements. Gulf Cans Industries values the flexibility to adapt reports and the SPC setup to challenges that the market asks for.
Results of Implementing Datalyzer SPC
“Our Shop Floor has access to the relevant process information to identify special causes of variation and quickly get back in-control in case of an OOC situation”
