Overall productivity increases by 14% in a cheese factory

CASE STUDY Overall productivity increases by 14% in a cheese factory Prepared by: Julie-Maude Arbour, 
 Business Analyst Get better control over your production with smart factory analytics. 
 Worximity Technology Inc. | 1-800 303-8453 | www.worximity.com | [email protected] SMART CHEESE MANUFACTURER Introducing a smart factory Amalgamated Dairies Limited Amalgamated Dairies Limited (ADL) has implemented the Worximity Smart Factory Analytics solution across 5 production lines. The result is a 14% increase in productivity. 
 Who they are Amalgamated Dairies Limited (ADL) is a producer-owned co-op with dairy processing and retail food distribution facilities. These plants process close to 26 million gallons of fresh island milk each year with a team of over 250 employees. CHALLENGE ADL had a sense that there were opportunities to improve production efficiency but weren’t able to gather the data that would uncover opportunities and point to solutions. They began to look for analytics solutions that would give them the insights they needed to take action. As they evaluated potential solutions they began to understand that they needed a solution that was as much ‘out of the box’ as possible and that would not take significant implementation resources such as IT, Engineering, Electricians and the like. Without a large training department, they needed an intuitive, easy to use solution that could provide users real-time actionable information while giving them a quick and continuing return on their investment. They also desired a solution that would provide anytime/anywhere real-time access to analytics so that they could empower decision-makers wherever they happened to be across their multiple sites. One goal was to implement a solution that would be applicable to all of their facilities and production processes. KEY OBJECTIVES Tyler Kowalski, Operational Improvement Coordinator at ADL, identified four primary goals for the company: Tying performance analytics to employee’s accountability and installing motivation to contribute to company improvement. He felt that by providing them with clear insights in real-time that they would be empowered to make quick decisions that add value to the business. Worximity Technology Inc. | 1-800 303-8453 | www.worximity.com | [email protected] "Worximity has allowed ADL to see what is truly happening in terms of production in real-time each day. We can now view downtimes and production speeds, which will help us continuously improve all of our production lines."  - Tyler Kowalski, Operational Improvement Coordinator He wanted to be able to take data from anywhere across the company and provide in the palm analytics that are customized to the role. A key success factor would be to count, record and reduce equipment downtimes 24/7 and improve production resource availability. Finally, he wanted to align management expectations to reality be confirming actual production rates, understand barriers to improving productivity and set achievable production goals. IMPLEMENTATION The Worximity Factory Analytics solution includes TileConnect smart sensors that are easily installed across a wide range of machinery. In this case ADL installed sensors on the output side of packaging equipment. The small form factor of the smart sensors enabled them to easily find suitable installation locations. Using high-accuracy optical sensors they were able gather production rate data in real- time. Worximity Technology Inc. | 1-800 303-8453 | www.worximity.com | [email protected] RESULTS THROUGH MONITORING JOURNEY Taking concrete steps towards significant costs reduction. The production lines vary in product type and packaging, ranging from wholesale and retail feta cheese, specialty cheeses such as Cheddar and Havarti, as well as grated cheese. Within a few months of real-time monitoring, ADL has increased its production capacity. Additionally, they are finding additional savings such as significantly reducing overtime. 
 " ACTUAL RESULT 7% increase in uptime and better responsiveness Worximity Factory Analytics allows ADL team to quickly fix problems. Uptime improves and productivity is on the rise. " TAKING ACTION $1,800/month reduction of downtime cost With the real-time dashboard and alerts, the team reacts faster to downtimes, reducing their length and occurence. 
 ACTUAL RESULT Reduced length of downtime by 15% Visualizing the amount of real-time downtimes allows the team to focus on the main causes. " TAKING ACTION Up to 23% decrease in direct labor cost per unit The efficiency of every employee can be increased by achieving and ultimately exceeding speed standards. 
 ACTUAL RESULT $0.15/unit savings in labor costs Being able to do more with the same resources, ADL provides more value with every employee. " TAKING ACTION Reduction of 17% of total production hours A significant increase in productivity makes it possible for ADL to minimize overtime as much as possible. 
 Worximity Technology Inc. | 1-800 303-8453 | www.worximity.com | [email protected] CLIENTS TESTIMONIALS Continuous improvement with real-time dashboard. Worximity Factory Analytics proved to be an great solution to easily and accurately monitor production output, downtimes and an array of KPIs that helps management make effective decisions, as well as actively involving employees in the process improvement measures. "Worximity has allowed ADL to see what is truly happening in terms of production in real time each day.  We can now view downtimes and production speeds, which will help us to continuously improve all of our production lines."- Tyler Kowalski, ADL, Operational Improvement Coordinator “Automated performance monitoring allows everyone to work more efficiently and focus their attention on what needs improving instead of collecting data or sifting through reports looking for anomalies. No more notepads, spreadsheets and hand-written reports trying to discover problems and implement changes. Everyone is at the same page at the same time.”* Dairy industry Trends** • The dairy industry is highly productive, very efficient and a large part of the economy. • The four major factors that influence profitability: production efficiencies, cost control, scale of operation and debt. Manufacturing IIoT Stats*** • 46% of industrial manufacturing respondents say they have already reached advanced level of digitization in product development & engineering • There are 2.9% additional revenue and 3.6% cost reduction expected from digitisation over the next five years. * http://blog.worximity.com/en/industry-4_0/increase-productivity-real-time-dashboards **http://www.omafra.gov.on.ca/english/livestock/dairy/facts/challeng.htm ***https://www.pwc.com/gx/en/industries/industrial-manufacturing/publications/assets/pwc-building-digital-enterprise.pdf Worximity Technology Inc. | 1-800 303-8453 | www.worximity.com | [email protected] BECOMING A SMART FACTORY Speeding up the process with IIoT According to several studies, the majority of manufacturing companies will have begun their industry 4.0 transformation by 2020 ... To avoid falling behind, start informing yourself now using our free tools! DOWNLOAD THE SMART FACTORY ANALYTICS EBOOK Download our 4 steps implementation e-book in order to discover the easiest and most effective way to start your digital transformation. Who should manage the project? Where and when to start? What should be measured What ROI you will get? YES, PLEASE. CALCULATE YOUR ROI A smart factory always improves the productivity...But by calculating your potential ROI, you will surely be more motivated to invest resources in your digital transformation. YES, PLEASE. BOOK A DEMO WITH OUR INDUSTRY EXPERT Ready to discover our smart manufacturing technologies? Pick the right time for you and it will be our pleasure to walk you through our product designed for manufacturers seeking to achieve the effectiveness level of a smart factory. YES, PLEASE. GET A QUOTE Fill in this small form to find out the real budget you'll need in order to benefit from the following: automatic collection of your production data, real-time data analysis and a simplified access to all your production data. YES, PLEASE. IDENTIFY THE CHAMPION IN YOUR TEAM It is important to identify a change champion, who “can be defined as a person working at any level of the organization who is skilled at initiating, facilitating, and implementing change. Download our checklist to easily identify your champion. YES, PLEASE.