About Stoelzle Glass
Stoelzle Glass Group is one of the world’s leading manufacturers of high-end glass packaging. With more than 200 years of history, the company operates six production sites across Europe and the US, and serves global customers including Pfizer and L’Oréal.
To maintain this standard despite macroeconomic pressure and rising customer expectations, Stoelzle sought new ways to improve line safety and utilization - while equipping its teams with better tools to resolve recurring issues faster and drive systematic continuous improvement.
The challenge
Glass production lines are fast-moving and complex, with process deviations occurring daily.
Glass gobs can go off path. Containers can get stuck in moulds, jam on conveyors, or fall and break during transport. If not addressed quickly, these issues lead to scrap, downtime, and in severe cases, machine damage, fires, or worker safety risks.
Because of the speed and complexity of the lines, manual monitoring alone made it difficult to detect, document, and resolve these incidents in time.
Stoelzle needed a solution that could:
- Continuously monitor critical production areas
- Detect deviations early
- Trigger preventive action in real time
- Automatically capture incidents and footage for root cause analysis
The solution
Stoelzle deployed Cerrion’s AI Agents across critical areas of three key production lines at its Czech Republic plant - from forming machines to conveyor belts.
Using standard CCTV cameras, Cerrion’s AI Agents monitor the production line in real time and detect as well as classify more than ten different process, quality, and safety deviations as they happen.
When an issue occurs - for example glass accumulations, tipped containers, malformed containers, flames, or jams - the Agent responds immediately:
- Real-time operator alerts Operators are alerted in real time via visual and audio alerts in their native language to speed up response and resolution time.
- Automated risk prevention High-risk events trigger automated, closed-loop interventions, such as rejecting bottles or stopping a machine section to prevent escalations and cut downtime as well as safety risks.
- Automatic incident documentation Every incident is automatically recorded, including video footage in Cerrion’s applications.
Operators and line leaders access actionable insights on those deviations directly on the production floor through Cerrion’s shop floor applications, enabling faster root cause analysis and more systematic continuous improvement.
“It is very helpful to have a system that records every single problem on the line. I use it to check what has happened when I was not there. Especially with inexperienced operators, we go through the detection and analytics applications to understand what actions are needed to make the machine deliver its best performance.”
Václav Petrik Line Supervisor, Stoelzle Glass
Impact and outcomes
- 1% increase in yield
- 6x+ annual ROI
- Automated closed-loop response to high-risk production issues
- Improved line performance within weeks of deployment
- Decision to roll out Cerrion globally across all facilities
From pilot to global rollout
Following the initial deployment, Stoelzle saw clear, measurable improvements in efficiency, safety, and operator performance - combined with strong adoption across operators, line leaders, and production management.
As a result, Stoelzle decided to roll out Cerrion globally across all six of its production facilities.
