Case Study

Scaling Up Smart Manufacturing With Tillit MES

An innovative recycling company using enzymatic reactions to break down plastics into their original chemical building blocks reused again into new plastic products.

Client

Samsara Eco

Project Type

MES Implementation

Location

ACT

The problem

Overview

As a growing manufacturer, Samsara Eco needed to scale operations while maintaining efficiency and product quality. They were transitioning from a research and development operation into a commercial production facility and their existing systems could not scale to support this new mode of working.

With rising demand, managing production schedules, SOPs, lab test results and staff training processes became increasingly difficult. Manual data entry created silos, and static Excel scheduling couldn’t be shared with the production team in real time.

Samsara Eco needed a streamlined, scalable solution where all these functions could be managed in one place, without the overhead of a complex enterprise system.

The solution

What we built

Production Scheduling

–Replaced spreadsheets with a drag-and-drop scheduling interface
–Incorporated BoM, production targets and asset utilisation
–Sales orders automatically converted into production runs

Work Order Management

–Standardised and digitised production SOPs
–Tasks and checkpoints allocated per operator, per workstation
–Full digital SOPs linked and accessible by all staff

QA / QC

–Centralised all quality and compliance checks into digital work forms
–Operators input production data directly against each production order
–Temperature checks, cycle times and abnormality reporting all logged

What was achieved

Results

Schedule Clarity

Live production schedule synchronised in real time between office and plant floor, reducing planning meetings and eliminating manual transmission of schedules.

50%

increase in production throughput per shift

Integrated Work Instructions

Digitised SOPs give clear instructions to frontline staff, maximising reaction efficiency and reducing the number of low-performing batches.

Instant

lab test result availability across all business units

Advanced Analytics

All process variables tracked per batch with full digital records, drastically improving traceability and eliminating manual data entry errors.

Zero

paper worksheets remaining on plant floor

I couldn’t believe how much was accomplished in just six weeks for Stage 1. The team did an outstanding job delivering results efficiently and effectively.

Diren Gokal — Head of Operations, Samsara Eco

The bigger picture

Conclusion

This project demonstrates how a tailored approach to automation can empower small manufacturers to overcome operational challenges and achieve sustainable growth.

By focusing on core production pillars and leveraging the adaptability of Tillit MES, we helped Samsara Eco transform their operations and position themselves for long-term success.

The flexibility of Tillit means the system can scale with their growth — without unnecessary complexity or cost.