Dairy Producer Increases OEE and Throughput with Real-Time Performance Management
Company Size
1,000+
Region
- Europe
Country
- Ireland
Product
- AspenTech Production Management & Execution (PM&E)
Tech Stack
- Real-Time Data Collection
- Data Analysis
- Performance Metrics Calculation
Implementation Scale
- Enterprise-wide Deployment
Impact Metrics
- Cost Savings
- Energy Saving
- Productivity Improvements
Technology Category
- Analytics & Modeling - Real Time Analytics
- Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries
- Food & Beverage
Applicable Functions
- Discrete Manufacturing
- Quality Assurance
Use Cases
- Predictive Maintenance
- Real-Time Location System (RTLS)
Services
- Data Science Services
- System Integration
About The Customer
Headquartered in Kilkenny, Ireland, Glanbia plc is a global ingredients and nutrition group. Glanbia Food Ingredients’ facility in Ireland processes about 1.4 billion liters of milk annually into butter, cheese, milk proteins, and whey derivatives. The company's management team challenged the Ballyragget, Ireland, facility to capture more of the available market opportunity without new capital expenditures. To do so, they needed to transform themselves into a high-performance facility to achieve “predictable excellence.”
The Challenge
Glanbia Food Ingredients’ facility in Ireland processes about 1.4 billion liters of milk annually into butter, cheese, milk proteins, and whey derivatives. Anticipated increases in milk supply meant that the plant would not meet processing demand in the near future, so Glanbia sought ways to improve production throughput in order to meet new expectations. Management decisions were based primarily on anecdotal information. Whenever a problem arose, managers would dig through log sheets and spreadsheets and talk to operators and engineers in an effort to determine the root cause of the problem. Each area had its own way of capturing the data and calculating and presenting performance metrics, which led to inconsistent and unreliable information. This lack of credible information resulted in less-than-optimal operating decisions. Improvement opportunities went unnoticed or were never acted upon because no one could determine the root cause of the problem.
The Solution
Working with Glanbia, the AspenTech solutions partner Orbis leveraged the AspenTech PM&E application to develop a performance management solution that collects data in real time and transforms it into highly visible, actionable information. The solution, powered by AspenTech’s PM&E application, provides value across the organization. Operators can visualize the impact of their actions in real-time. Process engineers can analyze events and trends, which helps continuously improve the process and rapidly resolve problems. Management is equipped to make fact-based decisions that optimize production operations. The team soon discovered that as acceptance of the system increased, people found more ways to use the information. Because of the unique design of the solution, users can easily create their own reports and analyses to help them improve the performance of their respective areas and to share with others in the organization.
Operational Impact
Quantitative Benefit
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