industry: food and beverage pepsi bottling ventures · pdf filepepsi bottling ventures of...

“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

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%.

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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