Human-Supervised CPS-Based Optimization of Insulation Material Production: An Industrial Case Study

Insulation-material manufacturers face increasing pressure to improve productivity, cost efficiency, energy performance and worker safety while maintaining stable quality in highly constrained production environments. Existing lean and smart-manufacturing studies often examine isolated tools, individual monitoring technologies or material-level sustainability, but fewer studies provide conservative plant-level validation of an integrated intervention in insulation-material production. This study therefore examines the optimization of insulation-material production in a human-supervised cyber–physical manufacturing system through an industrial before–after intervention. The framework combines bottleneck identification, value stream mapping, SMED, selective automation, preventive maintenance and KPI-based digital monitoring. The baseline system was constrained by manual crusher loading, long changeovers, inefficient pallet transport, repeated breakdowns, scrap and limited real-time visibility. After implementation, productivity increased from 7864 to 9000 kg/day (+14.5%), monthly production costs decreased from EUR 200,000 to EUR 180,000 (−10%), breakdown frequency fell from 5 to 3 events/month (−40%), scrap decreased from 5% to 3% (−40%), crusher loading time fell from 30 to 10 min/pallet (−66%), annual energy use dropped from 500 to 450 MWh (−10%) and reported safety incidents decreased to zero during the 12-month post-implementation observation period. An OEE-based surrogate model yielded pre- and post-state theoretical capacity estimates differing by less than 1%, supporting internal consistency. The results are interpreted as descriptive and practically meaningful before–after differences because the full raw monthly dataset is commercially sensitive and classical inferential testing was not performed. The study contributes by presenting a reproducible, conservative and human-supervised CPS-oriented plant-intervention protocol rather than by claiming a fully autonomous closed-loop CPS.