When chocolate manufacturer Barry Callebaut began its digital transformation journey seven years ago, Barry Callebaut chose AVEVA software to create the digital backbone of its smart factory initiative. The company wanted to improve traceability, reduce energy usage, and increase productivity across its factories. At its first implementation sites, Barry Callebaut used AVEVA System Platform to integrate multiple, complex data sources in real time. The improved communication and planning based on production line insights meant it identified previously unknown production capacity, allowing the business to maximize production on its existing factory lines.
"AVEVA products for us are very much at the center of our digital transformation journey.”
Bram Van Genabet,
Global Digital Manager, Barry Callebaut
Goals
- Institute a smart factory program that connects its ERP to product production lines
- To improve traceability, go fully paperless, and increase productivity
- Reduce energy consumption to reach sustainability goals
Challenge
- Mergers and acquisitions had resulted in multiple PLCs, all of which needed to be connected
Solutions
- Management of complex data sources in a standardized single truth model with AVEVA™ System Platform, AVEVA™ Historian and AVEVA™ Manufacturing Execution System
- Modular and scalable solution applied to multiple factories and gave operators a unified experience globally
Results
- Production line insights identified the opportunity to improve production capacity by 10%
- Predictive models revealed optimization opportunities that allowed lines to be adjusted in real time
- Reduced energy use to better meet net-zero goals
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