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IoT Implementation in Food Manufacturing: A Case Study of C.H. Guenther
Technology Category
- Functional Applications - Computerized Maintenance Management Systems (CMMS)
- Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries
- Education
- Packaging
Applicable Functions
- Maintenance
Use Cases
- Time Sensitive Networking
- Virtual Training
Services
- Training
The Challenge
C.H. Guenther, a large food manufacturer with a history of over 150 years, faced significant operational challenges in their Pioneer Frozen Foods plant in South Carolina. The plant, which employs over 200 people and has four main production lines, relied heavily on radio and face-to-face communication among workers. The lack of technological devices on the shop floor led to limited visibility and inefficiencies, with many issues going unnoticed and unresolved. A recurring problem on one of their lines, where the product was not being correctly deposited into the packaging, was causing regular three-minute stops. These minor stops, while seemingly insignificant, added up to approximately 40 hours of lost production time over a year. Additionally, the plant faced potential downtime due to a lack of trained employees to operate a new workstation.
About The Customer
C.H. Guenther is a well-established food manufacturer with over 150 years of operation. The company's Pioneer Frozen Foods plant, located in South Carolina, began operations in 2002 and currently employs over 200 individuals. The facility is equipped with four main production lines that are responsible for the production of a variety of products including dry mixes, doughs, pancakes, and cinnamon rolls. Prior to the implementation of Poka, the plant relied on traditional communication methods such as radio and face-to-face conversations, which led to several operational inefficiencies.
The Solution
The company implemented Poka, a connected worker app, to modernize their operations. This provided their workforce with access to iPads on the shop floor, enabling them to capture and share issues through pictures and videos. This visual support helped the maintenance team to quickly identify and solve problems. For the recurring line issue, a call for help was created on Poka, including a video showcasing the problem. This visibility led to a maintenance head suggesting a solution that permanently fixed the issue. To avoid downtime due to untrained employees, the company used Poka to provide access to the workstation’s standard work instructions. This allowed an untrained employee to operate the new workstation within an hour, significantly reducing potential downtime.
Operational Impact
Quantitative Benefit
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