DIGITAL BEVERAGE
OPERATIONS
Taking beverage operations
efficiency to the next level.
For decades a Food & Beverage Company, and many other FMCG enterprises, have pursued this mastery using Lean Six Sigma and similar continuous improvement processes, but Intelligent Industry (aka Industry 4.0) technologies have opened up new and exciting possibilities.
Intelligent Industry doesn’t mean abandoning tried and tested methods though. Intelligent Industry and Lean Six Sigma are highly complementary. Using them together has the potential to take production efficiency to levels never seen before.
For example, PDCA and Root Cause Analysis, Gemba Genbutsu (“go and see”), and the Five Whys are excellent tools, but can fail in complex processes where it is hard for a human to see what caused a failure. Data from Intelligent Industry technologies can close that gap.
Total Productive Maintenance is also excellent practice but relying on the operator’s senses and visual inspections to anticipate equipment failures has obvious limitations. Again, Intelligent Industry technologies can provide illuminating data that line operators can’t get on their own.
1. Monitoring and control of bottling operations
Intelligent Industry technologies collect data In many locations simultaneously, including locations people can’t see, and makes all of it available in real time. This level of visibility and control cannot be achieved by a human 1.0.
2. Bottling performance prediction
Detecting the root cause of issues in a few hours or days rather than a few weeks or months is also highly desirable. An integrated and automated flow of data from your plant enables high prediction confidence – revealing small problems before they become big ones, and visibility into spots inaccessible to humans.
3. Operator training
The seasonal or marketing-led ramp ups common in the beverage industry can require rapidly onboarding large numbers of new operators. Remote, simulated training ensures new people have foundational competencies before they even step on the shop floor.
Digital visualisation tools can support technicians in real time as they carry out maintenance. A technician can augment his capabilities with instant, mobile access to manuals and/or through remote assistance from an expert who could be on the other side of the world
4. Intelligent process automation
State of the art manufacturing technology can relieve operators from tedious, tiring activities and reduce safety risks on the shop floor, as well as ensuring precise and stable processes.
3. Operator training
The seasonal or marketing-led ramp ups common in the beverage industry can require rapidly onboarding large numbers of new operators. Remote, simulated training ensures new people have foundational competencies before they even step on the shop floor.
Digital visualisation tools can support technicians in real time as they carry out maintenance. A technician can augment his capabilities with instant, mobile access to manuals and/or through remote assistance from an expert who could be on the other side of the world
Real-world scenarios
Real life isn’t like the brochures. Enterprises are rarely able to implement every improvement they would like all at once. These three scenarios, based on real examples, show how implementing just some elements of Intelligent Industry can have a big impact.
A Food & Beverage Company with over 300 factories worldwide digitally rewires its supply chain to drive more reliable and responsive operations and reduce manufacturing costs. Using a state-of-the-art IoT platform that enables the collection and analysis of data about their operations, the company designs, implements, and deploys a connected factory solution to shorten the time between failures and resolutions.
A FMCG Company adopts enhanced Total Productive Maintenance (TPM) by applying artificial intelligence to sensor data from its industrial information systems. The system predicts quality problems and maintenance needs before they occur, helping achieve 80% breakdown avoidance, a 45% reduction in defects, and a 40%+ reduction in maintenance costs.
A beer manufacturer implements an automated intra logistics solution and optimises its production line material feeding efficiency by deploying Automated Guided Vehicles/Automated Intelligent Vehicles (AGV/AIVs). This solution doubles productivity (in hectoliters per person year)
Conclusions
The techno-focused hype around Intelligent Industry can make it sound alien to the pragmatic, hands-on methodologies that have served beverage production experts so well for decades, but in fact the two approaches work extremely well together.
Stripping away the hype reveals a set of tools that extend the effectiveness of the same methodologies experts have honed and relied on since the 1980s.
Intelligent Industry technologies can take us closer to the ideal of zero defects, zero breakdowns, zero waste and 100% on-time delivery than we ever thought possible.
Intelligent Industry and Lean Six Sigma are highly complementary. Using them together has the potential to take production efficiency to levels never seen before.
Intelligent Industry technologies can be thought of as augmenting the human processes and faculties that underpin Lean Six Sigma.
Intelligent Industry technologies can take us closer to the ideal than we ever thought possible
For more information, please contact
SANJAY ARORA
SALES DIRECTOR, CONSUMER PRODUCTS & RETAIL CAPGEMINI ENGINEERING sanjay.c.arora@capgemini.com
VALERIO DI GIOVANNI
HEAD OF PRESALES, INTELLIGENT OPERATIONS CAPGEMINI ENGINEERING valerio.digiovanni@capgemini.comLinkedin: https://www.linkedin.com/in/valerio-di-giovanni-03b5922//
About Capgemini
Capgemini is a global leader in partnering with companies to transform and manage their business by harnessing the power of technology. The Group is guided everyday by its purpose of unleashing human energy through technology for an inclusive and sustainable future. It is a responsible and diverse organisation of 270,000 team members in nearly 50 countries. With its strong 50 year heritage and deep industry expertise, Capgemini is trusted by its clients to address the entire breadth of their business needs, from strategy and design to operations, fuelled by the fast evolving and innovative world of cloud, data, AI, connectivity, software, digital engineering and platforms. The Group reported in 2020 global revenues of €16 billion.
Get the Future You Want | www.capgemini.com
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A global team of >50,000 engineers and technologists for our clients to solve their most complex intelligent industry challenges.
