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“With more detailed data available from the PLCs in real-time, we are able to cost-justify upgrade projects specifically for certain machine centers. We’re able to prove the need for more capital investment.”
Chris Bacon Project Manager
Bottling Plant Decreases Downtime and Achieves Swift Payback with Wonderware Software Solution
Goals•Improvechangeoverperformancebyaccurately identifyingconstraintsandbottlenecks•Facilitatebetterdecisionmakingforcross-functional teamsthroughconsistentandreliabledatawhich wouldeliminateguessworkandassumptions•Understandpaybackmetricsandusethisdatato justifyfutureprojectsrequiringcapitalinvestment
Challenges•Thenewplantrequiredtheintegrationofnew andlegacyequipment•Downtimedatawasrecordedmanually,andthis trackingsystemdidnotincluderecentlyinstalled equipment•Aleanheadcountmeantthatengineers’timewas atapremium
Wonderware Solution•WonderwareSystemPlatform•WonderwarePerformanceSoftware•WonderwareInTouch®HMI•WonderwareActiveFactory™Software•WonderwareHistorianSoftware
Results•ReportsandtrendingcapabilitiesofWonderware solutionenabledcross-functionalteamstoreview performancedatainconsistent,reliableandeasily sharedformats•Causeofdowntimeinchangeoverprocessidentified, leadingto50%reductioninchangeovertimeand additionalsavingsinrawmaterialsandpackaging•Planthasachievedanoverall10%increaseinline efficiency•Totalpaybackforinvestmenttooklessthanoneyear; annualizedsavingscalculatedatover$78,500
INDUSTRY:FOODANDBEVERAGE
Pepsi Bottling Ventures of Idahowww.pepsibottlingventures.com
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Nampa, Idaho –Intheconsumermarketplace,constantlychangingtastesdriveinnovation.Thisprincipleplaysout–literally–inthebeveragebusiness,whereofferingamultitudeofsoftdrinkchoicesisamainstayofgrowthandsuccess.
PepsiBottlingVentures(PBV)manufacturesanddistributesmorethan100differentflavorsandbrands.In2009,BeverageIndustrymagazinenamedPBVitsBottleroftheYear.ThecompanyhasbecomethethirdlargestmanufactureranddistributorofPepsi-ColaproductsinNorthAmerica,operating27bottlinganddistributionfacilitiesinsixstates.
InIdaho,PBVrunsastate-of-the-artmanufacturingandsalesdistributionplantinNampaaswellasthreeotherdistributioncentersthroughoutthestate.AndevenasanewmemberofthePBVfamily,joininginearly2009,thisdivisionhascontributedtothecompany’saward-winningoperationswithimpressiveperformanceandresults.
Integrating the Present with the Future
TheNampafacilitywasbuiltin2005andwasequippedwithacombinationofnewandlegacymachinery.Blendingtheseassetsprovedpossible,butissuesofwasteanddowntimewereapparent.
Additionally,ahomegrowndatacollectionsystemthathadbeeninplaceforthelegacyassetsdidnottakefulladvantageofthecapabilitiesofthenewequipment.Operatorstrackeddowntimeandrecordeditmanuallyduringtheirshifts.Relyingon
theseclipboardnotessometimesledtoinconsistentdecisionmakingandaninabilitytotracktrendsaccuratelyovertime.
ButPBVdidn’tacceptthissituationforlong.Theyknewthatbettersolutionswereavailable.Theirvisionincludedaperformancemanagementanddowntimetrackingsystemthatwouldconnectalloftheequipment,andthatwouldalsohelpthemquantifyreturnoninvestmentandjustifyfutureplantupgrades.
WonderwareCertifiedSystemsIntegratorApexManufacturingSolutionsworkedwithWonderwarePacWesttoassistPVBinevaluatingthepossibilities.ItbecameclearthatWonderwaresoftwarewasthepreferredsolutionwhenApexSeniorProjectManagerErikPhillipsrecommendedit,andChrisBacon,PBVProductionManager,confirmedpriorpositiveexperienceswiththeWonderwaresolution.
Thesolution–featuringtheWonderwareSystemPlatform,WonderwarePerformancesoftware,WonderwareInTouchHMI,WonderwareActiveFactoryandHistoriansoftware–wasinstalledinSeptember2008,andcommissionedandvalidatedjustonemonthlater.
Concentrating on Changeovers
Withsuchawidevarietyofproducts,makingsmoothswitchesbetweenformulationsiscentraltotheplant’sproductivity.BeforetheWonderwaresoftwaresolutionwasinstalled,engineersestimatedthatchangeoverstook60minutes.Withthenewsysteminplace,thedatashowedactualtimetoswitchbetweenflavorsaveraged90minutes.
Realizingthatthisdegreeofdowntimewasputtingadamperonprofitability,PBVusedtheWonderwaresoftwaretoidentifythechiefconstraintsandtheirrootcauses.Armedwiththisdata,theydeterminedthatthemostcriticalbottleneckwasinthefillerprocess.Correctingthisissueimprovedchangeoversbyupto45minutesandresultedinadditionalsavingsinrawmaterialsandpackaging.Efficiencyonthefillerlineincreasedby10%.
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Calculating Payback
UnderstandingreturnoninvestmentisimportantforPBVonaday-to-daybasis,butevenmorevaluablewhenitcomestoplanningforinvestmentsthatwillensuretheoperation’scontinuedsuccess.Especiallynow,capitalexpendituresarescrutinizedcloselyandthosethatcannotbejustifiedfortrueROIareindanger.
Afterseeingtheimprovementsinthefillerlineperformance,PBVusedWonderwaresoftwaredatatoconductanROIanalysis:
Projected Actual
Investment $85,000 $76,219
AnnualizedPayback $67,334 $78,548*
PaybackTime 1.25years .97years
*Includesadditionalsavingsinrawmaterialsandpackagingresultingfrommoreefficientchangeovers.
PBVwillusethisexperiencetosustaintheirContinuousImprovementprocessaswellastoidentifyfutureopportunitiestoinvestincapitalimprovementsthatcanbejustifiedbasedonROI.
The Best Solution
Justlikeconsumersselectingasoftdrink,PBVhadanumberofchoicestoconsiderforitsnewmanufacturingperformancesystem.Appealingqualitiessuchassuperiordatacollectionandanalysiscapabilities,easy-to-understandHMIvisualizationandefficientprogramminghelpedthebottlerchooseWonderwaresoftware.AndlikearefreshingPepsi,addingWonderwaresoftwaretothePBVNampaoperationprovidedimmediatepositiveresults.Butitwillalsocontributetolong-lastingperformanceimprovementsandverifiablereturnsoninvestment.
Teamwork for Continuous Improvement
Justasimportantly,theWonderwareHistorianprovidesreportsandtrendingtoolsthatenablecross-functionalteamstoanalyzeplantoperationsconsistently.Maintenance,operationsandengineeringstaffmemberscandependonaccurate,reliabledata,whichtakesguessworkandassumptionsoutoftheprocess.
PVBpersonnelshareanoverallviewofoperationswiththeWonderwareInTouchHumanMachineInterface(HMI)software.Agraphicalvisualizationoftheplantmakesoperationaltasksintuitiveandfacilitatesclearcommunications.Italsomakesthesystemeasyfornewoperatorstolearn.
Likemostmanufacturingbusinesses,PBVmaintainsaleanheadcount.SoWonderwaresoftware’sobject-basedprogrammingenablesmoreworktobedonebyfewerengineers,speedingthedevelopmentprocessandmakingitasefficientaspossible.Whenanewassetorlineisadded,existingprocessescanbequicklyandeasilyreplicatedthankstoWonderwaresoftware’sstandardization.
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