Polonia Mill: from four siloed buildings to one live dashboard

Polonia Mill has been operating in Łódź since 1934. Across four buildings on a single campus they run knitting, dyeing, finishing and quality control as four very independent organisations — each with its own paper logs, its own way of counting OEE, and its own private idea of how the previous shift went.

The brief from their operations director was small in words and large in scope: I want to know what is happening in any of these four buildings without leaving my office. Eight weeks later, every machine on the site reports live to a single Profna Flow dashboard, and the four buildings have a shared definition of a stop, a defect and a shift.

The technology was the easy part. The harder work was sitting in each building's break room, watching how operators actually used the existing paper logs, and then designing a digital workflow that respected those habits instead of replacing them on day one.