Food and beverage
In food and beverage everything is at stake at once: the line has to run, hygiene allows no shortcuts, and the cost per unit produced is watched closely. And the campaign does not wait. We work on line performance, equipment reliability and the data behind the decisions, which in this sector is usually the weakest link.
What we find in this sector
Seasonal campaigns in which an hour of downtime is never recovered.
Many formats and frequent changes, where the changeover and maintenance compete for the same window of time.
An OEE figure that is declared but not measured: micro-stoppages nobody records and waste booked at the end of the month.
Hygiene and food safety requirements that determine materials, lubricants, methods and cleaning times.
Industrial refrigeration and utilities that weigh heavily on the energy bill.
Raw materials and spare parts stores oversized «just in case» and, even so, stock-outs on the critical items.
Measurement and improvement of OEE by line, with micro-stoppages finally counted.
Reduction of changeover times and of line start-ups and stoppages.
An organisational model based on autonomous production units and daily management by indicators.
Standardisation of methods and the Production Operating Manual (MOP), so that the night shift works like the morning shift.
Raw materials warehouse analysis: cover, rotation, batches and synchronisation with the manufacturing programme.
Reduction of operating cost per unit produced.
Maintenance plans by line and by criticality, matched to the campaign calendar.
Preparation and planning of maintenance shutdowns between campaigns.
Predictive maintenance on rotating machinery, industrial refrigeration and compressed air.
Root cause analysis of the failures that come back campaign after campaign.
Optimisation of the spare parts store and of the critical stock policy.
Energy efficiency in refrigeration, compressed air and utilities.
Implementation of MES/CMMS systems (MES/GMAO) that capture the reason for a stoppage at the moment it happens.
Integration with SCADA to calculate line performance without manual work.
Connection with the ERP and the warehouse system to close off cost by batch and by line.
A plant dashboard shared by production and maintenance.
Batch and raw material traceability usable for management, not only for quality.