Customer Case: Royal Mosa
Tiles, tiles on the wall, who delivers customization to all?
Royal Mosa is a tile factory with a long history. The company is located in Maastricht where during the first industrial revolution De Sphinx, the very first factory in the Netherlands, was founded by the well-known industrialist Petrus Regout. Royal Mosa was founded in 1883 by Hubert Gérard Louis Regout, son of Petrus, and together with his son Louis he started a porcelain factory. After the Second World War, the demand for porcelain decreased and they changed their focus to the production of ceramic wall and floor tiles.
Today, Royal Mosa is a big name in the world of design with a rich collection of innovative products for floors, walls, façades and terraces. Approximately 6 million square meters of tiles annually find their way to customers in 30 countries, spread over 4 continents. This market positioning, in combination with its pursuit of sustainable production according to the cradle-to-cradle principle, ensures that Mosa is continuously improving and adapting their primary processes in line with the wishes of the customer. These wishes become more and more specific and there is an increasing demand for customized solutions requiring collaboration with architects and project consultants. This not only means a different way of working for the marketing and sales department, the factory also has to become proficient in the effective and efficient production of smaller batches.
In order to be able to respond to those specific questions from the market, Mosa now has Design Studios in Amsterdam, London, Frankfurt and Berlin, where architects and project advisors are being adviced. This personal approach is supported online by the website where clients and real estate developers can not only download brochures, but can also use a Pattern Generator to create a personal and contemporary design. Housing corporations or project developers can use the Mosa Composer to guide their customers in their choice. And with the Mosa Mix Calculator, the right number of tiles per type or color can be calculated on the basis of the chosen pattern. In this way Mosa can respond to the individual wishes of the customer online and offline.
But everything that is sold must also be produced, and we already stated that by responding to the personal wishes of the customer, the batch sizes become smaller and smaller. How should a tile manufacturer organise itself to produce smaller batces effectively and efficiently? We already thought you knew: by digitizing the production process! By retrieving measurement data throughout the production process, using sensors, collecting it in a so-called ‘Data Lake’ and then analyzing it using Big Data tools, Mosa gains an increasingly accurate picture of which critical measured values are decisive for the quality of the final product. This means that it can not only focus on improving that quality, but also intervene at the right time if the quality threatens to be negatively affected. This results in real-time quality control of the process instead of afterwards product control, which can save a lot of time and money. Moreover, the entire production process can also be controlled in such a way that disruptions can be prevented by means of ‘predictive maintenance’, or Industry 4.0 as we call it, as we live in the era of the 4th industrial revolution. The factory uses digitization of the production process to improve quality and that at the same time enables them to produce customized products instead of mass production. In the absence of ‘Economies of Scale’, Mosa can also strive for ‘Operational Excellence’ in order to produce as effectively and efficiently as possible, while at the same time meeting the personal wishes of the customer. Tiles, tiles on the wall, MOSA delivers customized products to all!