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Blending the right reasons with GainSeeker Suite to make a sensible investment
Technology Category
- Functional Applications - Manufacturing Execution Systems (MES)
- Analytics & Modeling - Real Time Analytics
- Automation & Control - Programmable Logic Controllers (PLC)
Applicable Industries
- Consumer Goods
- Packaging
Applicable Functions
- Process Manufacturing
- Quality Assurance
Use Cases
- Predictive Maintenance
- Machine Condition Monitoring
- Process Control & Optimization
Services
- Software Design & Engineering Services
- System Integration
The Challenge
The engineering and quality leaders at a consumer goods packaging company saw an opportunity to increase throughput and profitability by automating the ingredient mixing process. The existing manual process involved significant downtime and inefficiencies, particularly during product changeovers, which required shutting down high-speed lines for 5 to 10 minutes multiple times a day. This downtime added up to a significant amount of lost production time. Additionally, the manual mixing process was labor-intensive and required meticulous documentation to meet regulatory requirements. The company needed a solution that would not only automate the mixing process but also ensure compliance with regulatory standards.
About The Customer
The customer is a consumer goods packaging company that has been in operation for several years. They have a strong focus on quality and efficiency, having previously implemented Lean Six Sigma projects to improve their processes. The company operates multiple high-speed production lines and is tightly regulated, requiring meticulous documentation to ensure product quality and compliance with federal regulations. The company has a solid business incentive to push for smaller production lots, which necessitates frequent product changeovers. They are committed to continuous improvement and are always looking for ways to increase throughput and profitability.
The Solution
The company implemented a new automated, continuous batch mixing process using computer-controlled (PLC) equipment and software. This new process eliminated the manual mixing of ingredients, reducing the workload in the mixing department by 25%. The GainSeeker Suite was used to collect data automatically from the PLCs that control the flow meters feeding the ingredients into the mix. GainSeeker calculated and stored all the necessary values, providing real-time information and a data historian to help understand and improve the process. This system allowed the Quality Manager to monitor trends and identify issues before they became problems, ensuring the correct formulation of products and compliance with regulatory requirements. The automated process not only improved efficiency but also provided the necessary documentation to meet regulatory standards, making it a sensible investment for the company.
Operational Impact
Quantitative Benefit
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