Saverglass produces high-end customized glass bottles for the premium wine and spirits markets, and used AVEVA solutions to develop Digital Factory, which has become its new production standard. For benchmarking, Saverglass ran three monitoring pilot lines at three of its production sites, ahead of a planned global roll-out, which resulted in some significant results. The team is now working on developing additional use cases across the full production cycle from the raw materials to the pallet, to deliver even more value.
"By developing our Digital Factory, we have created a real community around data and performance. Digital factory is no longer a project - it’s our new production standard."
—Théo Rolland
Industrial Project Manager, Saverglass
Challenges
- Reduce energy and improve productivity but the lack of energy monitoring and process data limited visibility of improvement opportunities
- Understand more about how complex glass-making processes impact on quality by correlating performance and process data
Solution
Saverglass streamlined data collection from multiple data sources across different types of equipment using AVEVA™ PI Data Infrastructure. The team used AVEVA™ PI System™ asset framework to standardize the modelling of industrial processes and facilitate duplication to multiple sites, and AVEVA PI Vision to present dashboards to operators and managers. The team also used AI and advanced analytics to determine golden batch parameters.
Results
- Reduced energy usage by up to 30%
- Reduced product defects by being able to respond to issues faster
- Improved product quality, achieved greater production stability and generated less waste as a result of improved data management
- Improved ramp-up times enabling new production runs to start sooner and orders to be completed faster
- Establish golden batch parameters to optimize settings for the highest quality, as demanded by its high-end designs
- Created a positive culture and community around the digital factory which helps with adoption
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