Idaho Pepsi Bottling Company
Bottling plant reduces downtime and achieves rapid return on investment
Pepsi, formerly Brad's Drink and Pepsi-Cola, is a sugary cola soft drink created in the United States and produced by the PepsiCo company. Its biggest competitor is the also American Coca-Cola.
Pepsi first appeared in 1893. Its inventor was the pharmaceutical chemist Caleb Dpeneavis Bradham, who prepared and sold the drink in his pharmacy in the American town of New Bern (North Carolina).
Known at first as Brad Drink (in Spanish: "Refresco Brad"), in 1898 its creator called it Pepsi Cola, in reference to the digestive enzyme pepsin and the kola nuts used in the recipe. Bradham's goal was to create a delicious soft drink that aided digestion and was a stimulant.
Goals
- Improve change performance by accurately identifying limitations and bottlenecks.
- Facilitate better decision making for cross-functional teams through consistent and reliable data, eliminating guesswork and assumptions.
- Understand payback metrics and use this data to justify future projects requiring capital investment.
Challenges
- The new plant required the integration of new and legacy equipment.
- Downtime data was recorded manually and this tracking system did not include newly installed equipment.
- A small staff meant that engineers' time was at a premium.
Solutions
- AVEVA™ Historian Clients,
- AVEVA™ Historian, System Platform,
- AVEVA™ MES Performance, InTouch HMI
Results
- Cross-functional team reporting and trending capabilities enabled by AVEVA software to review performance data in consistent, reliable, and easily shared formats.
- The cause of downtime in the changeover process is identified, leading to a 50% reduction in changeover time and additional savings in raw materials and packaging.
- Full recovery of the investment took less than a year.
Pepsi Bottling Company of Garner, North Carolina
Pepsi bottling plant reduces downtime, improves quality
Goals
- Develop a performance and downtime tracking system.
- Eliminate guesswork and assumptions by collecting consistent, reliable data.
- Justify return on investment for future capital plant projects
- Develop an enterprise-grade platform for future expansion.
Challenges
- Implement the new system on 1 new line and 4 legacy lines in the plant.
- Downtime data was recorded manually and information collection was subjective and inconsistent
- Manually recorded data raised more questions than answers.
Solutions
- AVEVA™ Historian Clients,
- AVEVA™ Historian, System Platform.
- AVEVA™ MES Performance.
- AVEVA™ InTouch HMI.
Results
- The solution helps achieve sustainability goals and helps reduce the plant's carbon footprint.
- Process visualization immediately available to all levels of management and plant personnel.
- Ability to discover, validate and quantify opportunities for future capital investments.
- Average filler runtime data facilitated an increase in production numbers.
- Pepsi bottling plant reduces downtime and improves quality.