Are you ready to join Generation i?
A new generation is rising, defined not by age or experience, but by the relentless desire for progress.
By harnessing trusted insight and ingenuity - your Industrial Intelligence - you can open up new avenues for growth, drive decarbonization, and reshape Consumer Products Manufacturing today and for the future.
Respond to changing market and regulatory requirements with agility and at scale, while improving productivity and profitability, through trusted insights that span your ecosystem.
Turn data into decisions
Transform disconnected data into decisive action.
Break down silos
Share integrated data across teams and systems.
Connect every link
Power collaboration and resilience throughout your value chain.
Turn insight into growth
Build new revenue streams and enable efficiencies.
Learn more about how AVEVA customers harness their Industrial Intelligence
- Maple Leaf Foods
- New Belgium Brewing
- Henkel
Maple Leaf Foods turned existing tech into increased yield
Maple Leaf Foods is Canada’s largest prepared meats and poultry producer. With a focus on sustainability, the company continuously seeks new ways to optimize operations across its supply chain, as they say, to streamline its processes “from gate to plate.”
Most recently, Maple Leaf Foods has overhauled the plant where it produces bologna and over 800 million hot dogs a year. The company wanted to ensure product consistency while improving yield and reducing waste on the production floor.
Leveraging technology that is already in place
Maple Leaf Foods partnered with Cygnus Consulting, an AVEVA System integrator, to develop a solution. The initial plan was to fit new IoT sensors to collect data and send it to the cloud for analysis with advanced analytics that would enable new levels of production efficiency. However, soon after the project began, the team realized that the existing AVEVA software (AVEVA™ Manufacturing Execution Software) used by Maple Leaf already provided the contextualized process data required, so there was no need to invest in new technology. This data could then be sent to Braincube and blended with AVEVA’s own advanced analytics, for deeper AI-powered analysis that built on the digital twin of the asset.
Combining and comparing data with digital twins to produce a golden batch
The team focused on specific use cases to determine how best they could reduce waste at various stages of production, from log length to slicing. The end goal was maximum product yields.
The solution enabled operators to adjust recipes weekly to get the optimal product. The benefits have accrued—the improvement in the size of the log limits waste; when the logs are put into the ovens, they’re coming out with the desired results—and Maple Leaf Foods is saving money on power by turning the ovens off early. The slicers are turning out maximum yield with less waste.
The project benefits included:
- A suitable return on investment quickly
- More advanced data analysis led to faster awareness and response on the production floor
- The ability to fine-tune recipes weekly for consistently high-quality products
Maple Leaf Foods harnessed its Industrial Intelligence to get more from its existing technology, optimizing operations and increasing yield.
New Belgium Brewing turned insights into agility
New Belgium Brewing Co. produces some of the world’s most popular craft beers, including Fat Tire and a multitude of other popular IPAs, Pilsners, wheat beers and ales. As demand scaled, the company faced the difficulties of keeping production running smoothly and product quality consistent across its multiple sites.
New Belgium’s brewing operations were rapidly reaching capacity, and we needed to identify both efficiencies and inefficiencies in our bottling lines so the brewery could maintain its operating schedule.
New Belgium needed to tackle the following challenges:
- The lack of real-time information on unscheduled downtimes at various equipment areas which caused production slowdowns
- Gaps in methods and processes hindering improvement initiatives
- With multiple facilities at different stages of digital transformation, New Belgium needed to ensure that beer from one facility was indistinguishable from beer produced at the next
The company turned to AVEVA software to empower the implementation of a series of manufacturing automation initiatives to streamline and improve its brewing and bottling facilities.
From disparate data to increased efficiency
New Belgium Brewing collected, contextualized, and analysed the huge amounts of data available through its existing systems, transforming it into actionable information. With enhanced visibility and real-time insights, the company was able to better track and manage production performance, run targeted improvements, and replicate automation processes.
Improving performance and meeting customer demand
New Belgium’s digital transformation, amongst other benefits, has increased OEE from 45% to 65% in just over two years and decreased downtime by more than 50%. The company has been able to achieve record production weeks while also maintaining 100% flavor-matched beers across its breweries.
AVEVA’s [software], coupled with New Belgium’s continuous improvement strategy, has increased our packaging line efficiency by 30%, saving us more than $400,000 annually in previously planned labor expenditures. It also has extended our packaging area capacity to about 1.3 million barrels each year. At this point, our approach to higher volumes is ‘bring it on’
By harnessing its Industrial Intelligence, New Belgium Brewing built a data-driven foundation that its team could replicate across facilities - increasing operational efficiency, delivering consistent quality, and providing flexibility and adaptability.
Henkel turned data into savings
Henkel, a global FMCG manufacturer, is a pioneer, reimagining and improving life today and for generations to come. This spirit led to the digital transformation of their Laundry & Home Care division to drive greater efficiency, and thereby greater sustainability.
Goals included reducing specific energy consumption, achieving ISO 50001 certification, and improving supply-chain resource efficiency by 5–6% annually, all the while maintaining growth.
However, Henkel’s challenges in data collection and communication across the supply chain would make attaining its goals difficult. A partnership with AVEVA led to an effective solution.
We adopted a digital backbone as this facilitates a vertical approach. It’s faster and ensures application roll-out quickly generates tangible business benefits.
An elegant device-agnostic solution
Henkel uses AVEVA software to enable its teams to capture and contextualize operational data, manage domain, database, application programs. Device integration is configured independently, without affecting the architecture. Engineers can seamlessly incorporate legacy hardware.
Teams installed more than 4,000 physical and virtual sensors, and more than one million data points are captured every day. Touch-screen devices instantly consolidate and contextualize relevant data, enabling operators to collaborate in real-time and identify problematic areas.
Now, operators can accurately measure energy use across the entire factory. They analyze results within meaningful parameters, empowering teams to take corrective action and reduce energy consumption.
AVEVA’s software delivers overall equipment efficiency (OEE) data that further increases productivity. Machine downtime information enables operators to target in-line improvements.
Payback and then some
Energy consumption decreased by 16% in 2020, leading to €8 million in annual savings and €37 million saved to date. The project achieved full payback within four years and quadrupled ROI after eight years.
Other benefits include a 15% improvement in overall equipment effectiveness (OEE), reduction of filling line waste and 100% label quality rate.
By putting industrial intelligence to work, Henkel transformed its Laundry & Home Care operations, driving sustainability and efficiency across its value chain.
Once we’d implemented the AVEVA-based EMS solution, the energy saved was equivalent to the capacity needed to support the three million inhabitants of Amsterdam and Vienna
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