Pepsi Bottling Ventures of Idaho - Wonderware

INDUSTRY: FOOD AND BEVERAGEPepsi Bottling Ventures of Idahowww.pepsibottlingventures.com“With more detailed data available from the PLCs in realtime,we are able to cost-justify upgrade projects specificallyfor certain machine centers. We’re able to prove the need formore capital investment.”Chris BaconProject ManagerBottling Plant Decreases Downtime and Achieves SwiftPayback with Wonderware Software SolutionGoals• Improve changeover performance by accuratelyidentifying constraints and bottlenecks• Facilitate better decision making for cross-functionalteams through consistent and reliable data whichwould eliminate guesswork and assumptions• Understand payback metrics and use this data tojustify future projects requiring capital investmentChallenges• The new plant required the integration of newand legacy equipment• Downtime data was recorded manually, and thistracking system did not include recently installedequipment• A lean headcount meant that engineers’ time wasat a premiumWonderware Solution• Wonderware System Platform• Wonderware Performance Software• Wonderware InTouch ® HMI• Wonderware ActiveFactory Software• Wonderware Historian SoftwareResults• Reports and trending capabilities of Wonderwaresolution enabled cross-functional teams to reviewperformance data in consistent, reliable and easilyshared formats• Cause of downtime in changeover process identified,leading to 50% reduction in changeover time andadditional savings in raw materials and packaging• Plant has achieved an overall 10% increase in lineefficiency• Total payback for investment took less than one year;annualized savings calculated at over $78,500

Nampa, Idaho – In the consumer marketplace,constantly changing tastes drive innovation. Thisprinciple plays out – literally – in the beveragebusiness, where offering a multitude of soft drinkchoices is a mainstay of growth and success.Pepsi Bottling Ventures (PBV) manufactures anddistributes more than 100 different flavors andbrands. In 2009, Beverage Industry magazinenamed PBV its Bottler of the Year. The companyhas become the third largest manufacturer anddistributor of Pepsi-Cola products in NorthAmerica, operating 27 bottling and distributionfacilities in six states.In Idaho, PBV runs a state-of-the-art manufacturingand sales distribution plant in Nampa as well asthree other distribution centers throughout thestate. And even as a new member of the PBV family,joining in early 2009, this division has contributedto the company’s award-winning operations withimpressive performance and results.these clipboard notes sometimes led to inconsistentdecision making and an inability to track trendsaccurately over time.But PBV didn’t accept this situation for long. Theyknew that better solutions were available. Theirvision included a performance management anddowntime tracking system that would connect allof the equipment, and that would also help themquantify return on investment and justify futureplant upgrades.Wonderware Certified Systems Integrator ApexManufacturing Solutions worked with WonderwarePacWest to assist PVB in evaluating the possibilities.It became clear that Wonderware software wasthe preferred solution when Apex Senior ProjectManager Erik Phillips recommended it, and ChrisBacon, PBV Production Manager, confirmed priorpositive experiences with the Wonderware solution.The solution – featuring the Wonderware SystemPlatform, Wonderware Performance software,Wonderware InTouch HMI, WonderwareActiveFactory and Historian software – wasinstalled in September 2008, and commissioned andvalidated just one month later.Concentrating on ChangeoversIntegrating the Present with the FutureThe Nampa facility was built in 2005 and wasequipped with a combination of new and legacymachinery. Blending these assets proved possible,but issues of waste and downtime were apparent.Additionally, a homegrown data collection systemthat had been in place for the legacy assets didnot take full advantage of the capabilities of thenew equipment. Operators tracked downtime andrecorded it manually during their shifts. Relying onWith such a wide variety of products, makingsmooth switches between formulations is centralto the plant’s productivity. Before the Wonderwaresoftware solution was installed, engineers estimatedthat changeovers took 60 minutes. With the newsystem in place, the data showed actual time toswitch between flavors averaged 90 minutes.Realizing that this degree of downtime was putting adamper on profitability, PBV used the Wonderwaresoftware to identify the chief constraints and theirroot causes. Armed with this data, they determinedthat the most critical bottleneck was in the fillerprocess. Correcting this issue improved changeoversby up to 45 minutes and resulted in additionalsavings in raw materials and packaging. Efficiency onthe filler line increased by 10%.

Teamwork for Continuous ImprovementJust as importantly, the Wonderware Historianprovides reports and trending tools thatenable cross-functional teams to analyze plantoperations consistently. Maintenance, operationsand engineering staff members can depend onaccurate, reliable data, which takes guesswork andassumptions out of the process.PVB personnel share an overall view of operationswith the Wonderware InTouch Human MachineInterface (HMI) software. A graphical visualizationof the plant makes operational tasks intuitive andfacilitates clear communications. It also makes thesystem easy for new operators to learn.Like most manufacturing businesses, PBV maintainsa lean headcount. So Wonderware software’s objectbasedprogramming enables more work to be doneby fewer engineers, speeding the developmentprocess and making it as efficient as possible. Whena new asset or line is added, existing processescan be quickly and easily replicated thanks toWonderware software’s standardization.Calculating PaybackUnderstanding return on investment is importantfor PBV on a day-to-day basis, but even morevaluable when it comes to planning for investmentsthat will ensure the operation’s continued success.Especially now, capital expenditures are scrutinizedclosely and those that cannot be justified for trueROI are in danger.After seeing the improvements in the filler lineperformance, PBV used Wonderware software datato conduct an ROI analysis:ProjectedActualInvestment $85,000 $76,219Annualized Payback $67,334 $78,548 *Payback Time 1.25 years .97 years* Includes additional savings in raw materials and packaging resulting frommore efficient changeovers.PBV will use this experience to sustain theirContinuous Improvement process as well as toidentify future opportunities to invest in capitalimprovements that can be justified based on ROI.The Best SolutionJust like consumers selecting a soft drink, PBVhad a number of choices to consider for its newmanufacturing performance system. Appealingqualities such as superior data collection andanalysis capabilities, easy-to-understand HMIvisualization and efficient programming helped thebottler choose Wonderware software. And like arefreshing Pepsi, adding Wonderware software tothe PBV Nampa operation provided immediatepositive results. But it will also contribute to longlastingperformance improvements and verifiablereturns on investment.

Contact Wonderware or your local Wonderware Distributor for information about software products for industrial automation.Wonderware • 26561 Rancho Parkway South, Lake Forest, CA 92630 • Tel: (949) 727-3200 • Fax: (949) 727-3270 • www.wonderware.com© 2009 Invensys Systems, Inc., All rights reserved. No part of the material protected by this copyright may be reproduced or utilized in any form or by any means,electronic or mechanical, including photocopying, recording, broadcasting, or by any information storage and retrieval system, without permission in writing fromInvensys Systems, Inc.Invensys, Wonderware, ArchestrA, InTouch, ActiveFactory and InBatch are trademarks of Invensys plc, its subsidiaries and affiliated companies. All other brands andproduct names may be the trademarks or service marks of their respective owners.Rel. 8/09