HMR-EPI Executive Overview

Executive Summary

AI-Powered Extrusion Process Intelligence

Executive KPI / Value Driver

3-12 months

Typical ROI

Up to €1.2M per year

Annual Improvement Potential

Up to +15%

Productivity Improvement

Up to -22%

Scrap Reduction

Up to -35%

Startup Time Reduction

Up to -12%

Energy Consumption

Why Customers Invest

Typical Challenges

Knowledge Loss

Operator Dependency

Process Instability

High Scrap

Rising Energy Costs

Long Startup Times

HMR-EPI Solution

Capture & Preserve Knowledge

Standardize Best Practices

Identify Root Causes

Optimize Processes

Improve Quality & Productivity

Achieve Measurable Results

Hybrid Intelligence for PVC Extrusion

Combining Human Expertise, Lean Six Sigma & Artificial Intelligence

Traditional Systems

System: SCADA
Typical Role: Collect Data

System: MES
Typical Role: Organize Data

System: ERP
Typical Role: Manage Business Data

System: Historian
Typical Role: Store Data

System	Typical Role
SCADA	Collect Data
MES	Organize Data
ERP	Manage Business Data
Historian	Store Data

HMR-EPI combines

Production Data
Historical Knowledge
Lean Six Sigma DMAIC
PVC Processing Expertise
Engineering Rules
AI & Machine Learning

Expertise of PVC Processing Specialists

Decades of PVC processing experience
Process engineering knowledge
Proven best practices
Historical problem-solving expertise
Expert-defined correlations
Root cause methodologies

AI Analytics Engine

Correlation Detection
Pattern Recognition
Root Cause Analysis
Predictive Analytics
Optimization Recommendations

Lean Six Sigma DMAIC

Define
Measure
Analyze
Improve
Control

Four Intelligence Areas

Formulation Intelligence

Ensure Consistency & Stability

PVC Resins & Additives
Suppliers & Specifications
Material Properties
Batch Variations
Formulation Optimization

Mixing & Blending Intelligence

Secure Input Quality

Addition Sequences & Timing
Mixing Temperatures (Hot / Cold)
Mixing Duration & Energy Input
Cooling Process
Intermediate Storage & Aging
Dryblend Consistency & Quality

Extrusion Process Intelligence

Control Processes & Maximize Performance

Process, Material & Environmental Variables
Temperatures, Pressure, Torque, Vacuum
Material Moisture & Temperatures
Inline Measurements & Quality Data
Wall Thickness, Density, Color, Gloss, Defects
Process Stability & Correlations
Anomaly Detection & Root Cause Analysis
Yield, Energy & OEE Optimization

Quality & Market Intelligence

Customer Satisfaction & Value Creation

Inline- & Laboratory QC Data
SPC & Trend Analysis
Customer Feedback & Complaints
Market & Long-Term Performance
Feedback into Formulation, Mixing & Extrusion

Typical Customer Journey - Modular & Scalable Implementation

Phase: Phase 1
Focus: Extrusion Process Intelligence
Scope: OEE Improvement; Startup Optimization; Scrap Reduction; Density Optimization; Throughput Optimization; Process Stability
Business Impact: Fastest ROI & Lowest Entry Barrier

Phase: Phase 2
Focus: Quality Intelligence
Scope: SPC Analytics; Quality Prediction; Complaint Analysis; Root Cause Analysis; Inline & Laboratory Data Integration
Business Impact: Improved Product Consistency & Reduced Claims

Phase: Phase 3
Focus: Mixing & Blending Intelligence
Scope: Dryblend Consistency; Mixing Optimization; Energy Optimization; Material Variability Reduction
Business Impact: More Stable Production Conditions

Phase: Phase 4
Focus: Formulation Intelligence
Scope: Formulation Optimization; Supplier Benchmarking; Cost Optimization; Long-Term Product Performance
Business Impact: Strategic Product & Cost Leadership

Phase	Focus	Scope	Business Impact
Phase 1	Extrusion Process Intelligence	OEE Improvement; Startup Optimization; Scrap Reduction; Density Optimization; Throughput Optimization; Process Stability	Fastest ROI & Lowest Entry Barrier
Phase 2	Quality Intelligence	SPC Analytics; Quality Prediction; Complaint Analysis; Root Cause Analysis; Inline & Laboratory Data Integration	Improved Product Consistency & Reduced Claims
Phase 3	Mixing & Blending Intelligence	Dryblend Consistency; Mixing Optimization; Energy Optimization; Material Variability Reduction	More Stable Production Conditions
Phase 4	Formulation Intelligence	Formulation Optimization; Supplier Benchmarking; Cost Optimization; Long-Term Product Performance	Strategic Product & Cost Leadership

How HMR-EPI Generates Recommendations

From Data to Explainable Operational Intelligence

Data Sources

Production Data
Historical Knowledge
Quality & SPC Data
PVC Processing Expertise
Engineering Rules
AI & Machine Learning

HMR-EPI Hybrid Intelligence Engine

PVC Expertise
Lean Six Sigma DMAIC
Historical Knowledge
Engineering Rules
Statistical Analysis
AI & Machine Learning

Analyze

Correlations
Root Causes
Patterns
Best Practices

HMR-EPI explains

Why the recommendation is made
Which data supports it
Which expertise was applied
Which correlations were identified
What improvement potential may be expected

HMR-EPI can explain

What was discovered

Why it matters

Which variables have the strongest influence

Which historical production runs support the recommendation

What improvement potential may be expected

Confidence level of the recommendation

How HMR-EPI Creates Measurable Improvements

SCADA collects data. HMR-EPI creates savings.

Traditional SCADA Systems

Capability: Collects process data

Capability: Displays trends & alarms

Capability: Monitors equipment status

Capability: Stores historical data

Capability: Generates reports

Capability
Collects process data
Displays trends & alarms
Monitors equipment status
Stores historical data
Generates reports

HMR-EPI Hybrid Intelligence

Production Data
Quality Data
Historical Knowledge
PVC Process Expertise
Lean Six Sigma DMAIC
Identifies hidden correlations
Recommends optimal actions
Finds root causes automatically
Optimizes operating windows
Detects process instabilities
Predicts quality & performance
Learns from best practices
Supports continuous improvement

How KPI Improvements Are Generated

Improvement: Scrap Reduction
How HMR-EPI Generates It: Detects root causes, process drift and quality correlations.

Improvement: Faster Startups
How HMR-EPI Generates It: Recommends proven startup parameters and best practices.

Improvement: Higher Throughput
How HMR-EPI Generates It: Identifies stable operating windows and process bottlenecks.

Improvement: Lower Energy Consumption
How HMR-EPI Generates It: Optimizes process settings and operating conditions.

Improvement: Higher OEE
How HMR-EPI Generates It: Reduces process instability and unplanned downtime.

Improvement: Better Quality
How HMR-EPI Generates It: Detects critical influencing factors before defects occur.

Improvement	How HMR-EPI Generates It
Scrap Reduction	Detects root causes, process drift and quality correlations.
Faster Startups	Recommends proven startup parameters and best practices.
Higher Throughput	Identifies stable operating windows and process bottlenecks.
Lower Energy Consumption	Optimizes process settings and operating conditions.
Higher OEE	Reduces process instability and unplanned downtime.
Better Quality	Detects critical influencing factors before defects occur.

From Data to Business Impact

Why HMR-EPI delivers results that SCADA alone cannot

Step: 1. SCADA
Content: Data Collection; Alarms; Trends; Historian
Answers: What happened?

Step: 2. HMR-EPI Intelligence
Content: Correlations; Root Cause Analysis; AI & Machine Learning; Lean Six Sigma DMAIC; Expert Knowledge; Process Models
Answers: Why did it happen? What should be changed?

Step: 3. Recommendations
Content: Prioritized Actions; Best Practices; Parameter Recommendations; What-if Analysis; Expected Impact
Answers: What will improve and how much?

Step: 4. Actions
Content: Operator Actions; Process Adjustments; Recipe Optimization; Preventive Measures
Answers: What actions to take?

Step: 5. Business Results
Content: -22% Scrap; -35% Startup Time; +15% Productivity; -12% Energy; +30% OEE; Better Quality
Answers: What is the business impact?

Step	Content	Answers
1. SCADA	Data Collection; Alarms; Trends; Historian	What happened?
2. HMR-EPI Intelligence	Correlations; Root Cause Analysis; AI & Machine Learning; Lean Six Sigma DMAIC; Expert Knowledge; Process Models	Why did it happen? What should be changed?
3. Recommendations	Prioritized Actions; Best Practices; Parameter Recommendations; What-if Analysis; Expected Impact	What will improve and how much?
4. Actions	Operator Actions; Process Adjustments; Recipe Optimization; Preventive Measures	What actions to take?
5. Business Results	-22% Scrap; -35% Startup Time; +15% Productivity; -12% Energy; +30% OEE; Better Quality	What is the business impact?

Potential Business Impact & ROI

Illustrative Examples Based on Industry Experience & Process Analytics

Up to €1.2M

Financial Impact

Illustrative improvement potential per line based on industry experience, process analytics and typical PVC sheet extrusion operations.

3-12 months

ROI Timeline

Typical ROI range depending on implementation scope, operating conditions, production volume and process maturity.

Potential Improvement Range

Area: Productivity Improvement
Potential: Up to +15%

Area: Scrap Reduction
Potential: Up to -22%

Area: Startup Time Reduction
Potential: Up to -35%

Area: Energy Consumption
Potential: Up to -12%

Area: Process Stability
Potential: Up to +30%

Area	Potential
Productivity Improvement	Up to +15%
Scrap Reduction	Up to -22%
Startup Time Reduction	Up to -35%
Energy Consumption	Up to -12%
Process Stability	Up to +30%

Measurable Impact

Clear KPIs and transparent performance tracking.

Fast ROI

Quick implementation with measurable results.

Sustainable Results

Continuous improvement and long-term value creation.

Competitive Advantage

Higher efficiency, lower costs and improved product quality.

Commercial Model (Illustrative)

Package: Pilot
Illustrative Price Range: €50k - €80k
Typical Scope: 1 Extrusion Line; Core Analytics; Quick ROI Validation
Timeline: 3-6 Months
Positioning: Prove Value

Package: Professional
Illustrative Price Range: €100k - €250k
Typical Scope: Multiple Lines; Advanced Analytics; Dashboards
Timeline: 6-12 Months
Positioning: Scale & Optimize

Package: Enterprise
Illustrative Price Range: €250k - €500k
Typical Scope: Plant / Site Wide; Full Intelligence Suite; Integrations
Timeline: 12-24 Months
Positioning: Enterprise Impact

Package: Corporate
Illustrative Price Range: €500k - €1M+
Typical Scope: Multi-Site / Global; Corporate Rollout; Advanced AI & Support
Timeline: 24+ Months
Positioning: Transform Globally

Package	Illustrative Price Range	Typical Scope	Timeline	Positioning
Pilot	€50k - €80k	1 Extrusion Line; Core Analytics; Quick ROI Validation	3-6 Months	Prove Value
Professional	€100k - €250k	Multiple Lines; Advanced Analytics; Dashboards	6-12 Months	Scale & Optimize
Enterprise	€250k - €500k	Plant / Site Wide; Full Intelligence Suite; Integrations	12-24 Months	Enterprise Impact
Corporate	€500k - €1M+	Multi-Site / Global; Corporate Rollout; Advanced AI & Support	24+ Months	Transform Globally

Architecture & Security

Layer: Data Sources
Elements: SCADA / DCS; BOOM SCADA (Optional); MES / ERP; LIMS / QC; Inline Devices

Layer: HMR-EPI AI Engine
Elements: AI / ML Models; Analytics Engine; Knowledge Base; Insights & Recommendations

Layer: Deployment
Elements: On-Premise; Air-Gapped Option; SCADA Independent; Customer Data Ownership

Layer	Elements
Data Sources	SCADA / DCS; BOOM SCADA (Optional); MES / ERP; LIMS / QC; Inline Devices
HMR-EPI AI Engine	AI / ML Models; Analytics Engine; Knowledge Base; Insights & Recommendations
Deployment	On-Premise; Air-Gapped Option; SCADA Independent; Customer Data Ownership

Flexible Integration

Secure By Design

Built For Industry

How HMR-EPI Applies Lean Six Sigma DMAIC

A structured methodology. AI-powered execution. Measurable results.

HMR-EPI embeds Lean Six Sigma DMAIC into a digital workflow, combining process data, domain expertise and AI analytics to continuously improve your PVC extrusion operations.

DMAIC Phase: Define
Objective: Define the problem and opportunity.
HMR-EPI Activities: Capture voice of customer and quality issues; Define problem statement and scope; Identify KPIs and goals; Build project charter; Map high-level process.
Output: Clear problem definition, goals and scope.

DMAIC Phase: Measure
Objective: Measure current performance.
HMR-EPI Activities: Collect and validate data from all relevant sources (SCADA, MES, QC, LIMS); Analyze process baseline and performance; Identify key input and output variables; Visualize performance with dashboards.
Output: Reliable data and current state understanding.

DMAIC Phase: Analyze
Objective: Analyze root causes and drivers.
HMR-EPI Activities: Correlation and multivariate analysis; Root cause analysis using AI and expert knowledge; Pareto analysis; Identify critical X factors (process, material, equipment, methods); Hypothesis validation.
Output: Verified root causes and key influencing factors.

DMAIC Phase: Improve
Objective: Develop and implement solutions.
HMR-EPI Activities: Generate and evaluate solution alternatives; Simulate and predict impact using AI models; Recommend optimal settings and actions; Implement solutions; Track short-term results.
Output: Implemented solutions with proven impact.

DMAIC Phase: Control
Objective: Sustain improvements and prevent regression.
HMR-EPI Activities: Monitor KPIs and process stability in real-time; Set up alerts and control limits; Standardize best practices; Document lessons learned; Continuously detect deviations and act early.
Output: Sustained performance and continuous improvement.

DMAIC Phase	Objective	HMR-EPI Activities	Output
Define	Define the problem and opportunity.	Capture voice of customer and quality issues; Define problem statement and scope; Identify KPIs and goals; Build project charter; Map high-level process.	Clear problem definition, goals and scope.
Measure	Measure current performance.	Collect and validate data from all relevant sources (SCADA, MES, QC, LIMS); Analyze process baseline and performance; Identify key input and output variables; Visualize performance with dashboards.	Reliable data and current state understanding.
Analyze	Analyze root causes and drivers.	Correlation and multivariate analysis; Root cause analysis using AI and expert knowledge; Pareto analysis; Identify critical X factors (process, material, equipment, methods); Hypothesis validation.	Verified root causes and key influencing factors.
Improve	Develop and implement solutions.	Generate and evaluate solution alternatives; Simulate and predict impact using AI models; Recommend optimal settings and actions; Implement solutions; Track short-term results.	Implemented solutions with proven impact.
Control	Sustain improvements and prevent regression.	Monitor KPIs and process stability in real-time; Set up alerts and control limits; Standardize best practices; Document lessons learned; Continuously detect deviations and act early.	Sustained performance and continuous improvement.

DMAIC Powered by HMR-EPI

AI-Enhanced Insights

AI and machine learning accelerate analysis and root cause identification.

Integrated Data

All relevant data sources combined for a complete process understanding.

Expert Knowledge

PVC processing expertise and proven methodologies built into the workflow.

Faster Results

Structured approach delivers results in weeks, not months.

Measurable Impact

Sustainable improvements in quality, productivity, cost and energy.

Why HMR-EPI?

Transforming PVC extrusion operations with AI-powered intelligence

Better Quality

Consistent. Reliable. Superior.

Faster Time to Market

Optimized Processes. Better Decisions.

Higher Productivity

Higher Output. Less Downtime.

Knowledge Retention

Capture Knowledge. Share Knowledge. Continuously Improve.

Lower Costs

Less Scrap. Lower Energy Consumption.

Sustainable Production

Efficient. Responsible. Future-Proof.

Transformation Flow: Data into Knowledge

Transformation Flow: Knowledge into Action

Transformation Flow: Action into Impact

Transformation Flow: Impact into Measurable Business Results

Transformation Flow
Data into Knowledge
Knowledge into Action
Action into Impact
Impact into Measurable Business Results