Case Study: ISOSPA Boosts EPS Manufacturing Efficiency with SkyMes Production Management
Sector: Rubber & Plastics
Introduction
Founded in Florence in 1984, ISOSPA has become a trusted Italian leader in the production and transformation of expanded polystyrene (EPS). With decades of experience, the company delivers tailored EPS solutions across multiple industries — from real estate and scenography to packaging, which has become a particularly strategic sector in today’s global economy.
To meet increasing demand and continue offering reliable, high-quality solutions, ISOSPA partnered with SkyMes to modernize its shop floor operations. By connecting their machines and implementing the Production Management module of SkyMes, ISOSPA achieved a new level of efficiency, transparency, and digital control.
The Challenge
ISOSPA needed to address key production challenges to remain competitive in a demanding marketplace:
Manual production oversight led to inefficiencies, errors, and delays in meeting customer delivery timelines.
Limited real-time visibility across operators, machines, and work orders made it difficult to track productivity and resolve issues quickly.
Growing need for data-driven decisions to optimize production resources, reduce scrap, and lower operating costs.
The Solution: SkyMes Production Management
SkyMes deployed its Production Management module, the heart of the MES, enabling real-time orchestration and supervision of all production operations on the shop floor. By digitally connecting ISOSPA’s machines and operators, SkyMes transformed production execution into a transparent, data-driven process.
Key Features Implemented:
Business model & product management
Work order management & electronic dispatching of tasks/documents
Automated production data acquisition
Paperless factory management with web-based operator workstations
Real-time monitoring & supervision of machines and operators
OEE (Overall Equipment Effectiveness) calculation & performance analysis
Integration with Grafana Business Intelligence for live reporting
Business Application Interface for seamless system integration
Advanced Planning & Scheduling (APS)
In addition to core production management, ISOSPA now benefits from APS capabilities, enabling smarter planning and scheduling of resources. This ensures balanced workloads, reduced lead times, and greater responsiveness to market demands.
The Results
With SkyMes Production Management in place, ISOSPA realized significant operational improvements:
Full real-time connectivity between machines, operators, and devices, enabling immediate insights into production status.
Reduced waste and scrap, thanks to better monitoring of resource efficiency and quality metrics.
Lowered production costs, achieved through digitalization, better planning, and optimized use of resources.
Enhanced OEE performance, improving equipment utilization and productivity across the plant.
Streamlined processes with paperless operations, increasing accuracy and reducing administrative overhead.
Benefits of Implementation
Efficient management of plant master data
Complete digitalization of production processes
Real-time monitoring of scrap rates, downtimes, work times, setups, and material consumption
Waste and cost reduction through improved efficiency
Improved scheduling with APS, leading to shorter lead times and greater flexibility
Conclusion
By connecting its machines and implementing the SkyMes Production Management module, ISOSPA has taken a decisive step toward digital transformation. The company now enjoys complete visibility into its shop floor, improved efficiency, and greater control over costs and resources. These advancements allow ISOSPA to deliver higher quality and more reliable EPS solutions to its customers across packaging, real estate, and industrial markets.
Company Website: ISOSPA
