SuccessStory_Wonderware_PepsiBottlingVenturesOfGarnerNC_03-13

7/28/2019 SuccessStory_Wonderware_PepsiBottlingVenturesOfGarnerNC_03-13

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We have to makethe right decisionseveryday because ithas a huge impacton our bottom line.Wonderware helps usmake those decisions

Scott Jamison

Vice President of Engineering

Pepsi Bottling Plant Decreases Downtime and Improves Qualitywith Wonderware Sotware Solution

Goals Develop a Performance and Downtime

tracking system Eliminate guesswork and assumptions through

collection of consistent and reliable data Justify Return On Investment for future capital

plant projects Develop an enterprise level platform for future

expansion

Challenges

Implement the new system across 1 new line and4 legacy lines in the plant

Downtime data was recorded manually andinformation gathering was subjective andinconsistent

Manually recorded data created more questionsthan answers

Solutions and Products Wonderware System Platform Wonderware Performance Software Wonderware InTouch HMI Wonderware ActiveFactory Software Wonderware Historian Software

Results Produce over 30 million cases of Pepsi

products a year PBV Garner has grown from producing &

distributing 189 different products to over 500 Total payback for investment estimated at 2.8 ye Solution assists in achieving sustainability goals

and helps reduce the plants carbon footprint Process Visualization immediately available to all

levels of plant management and staff Ability to discover, validate and quantify

opportunities for future capital investment Average Filler Runtime data facilitated increased

production numbers

INDUSTRY: FOOD & BEVERAGE

Pepsi Bottling Ventures o Garner, North Carolinawww.pepsibottlingventures.com
http://www.pepsibottlingventures.com/http://www.pepsibottlingventures.com/


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Line Efciency and Product Quality

PBVs wide range of products, with ongoingpackaging and avor changeovers, makesline efciency a primary objective. Before theimplementation of Wonderware throughout theplant, line efciency was an evasive concept.Operators were never quite sure if they were ahead

of or behind schedule. Therefore, the scheduling ofchangeovers was a guessing game.

Today, the data collected by Wonderware is drivingline efciencies. By pinpointing downtime, PBVcan gain percentage points against efciencies.By driving efciencies up, costs are driven down.Overall production improvement across all ve linesenables PBV to focus their resources on meetingand maintaining Pepsicos quality guidelineswhile ensuring that production goals are met onschedule.

Access to Accurate Data= Production ImprovementJust as important as accuracy of data is accessibilityto data. Real-time production data is displayedthroughout the plant, production ofce and evenin the employee break room on large, at-screendisplays. PBV has found that workers are payingattention to what is happening on their lines, even

while on break, and know whether they are aheadof schedule or behind. This motivates them tocontinually monitor their line efciencies and makeadjustments as necessary to meet their goals.

The Wonderware solution is used across all ve linesin the facility to great success. On-going access topertinent information enables plant personnel toanalyze production data, make informed decisionsand implement successful solutions.

By using Wonderware, PBV has been able tooptimize employee performance by tailoringtraining based on hard data rather than subjectiveopinions. By improving machine operatorperformance, line mechanics now focus on overallline performance rather than machine or operatorbased issues.

Sustainability Goals are achieved throughPerormance with Purpose

The Wonderware Performance Software operatingat PBV generates machine efciency data on an on-going basis. With an eye toward sustainability, PBVutilizes this data to minimize their impact on theenvironment and maximize the efciency with which

they use raw materials. Pepsicos Performancewith Purpose program is focused on sustainabilityand striking a balance between environmental,economic and social concerns.

PBV recognizes that good environmental practiceis also good business: the fewer raw materials theyuse, the less waste they produce, the less electricitythey use the lower their costs. This makes for ahealthier business model and a healthier planet.

Success or the Best

Wonderware Performance Software provides anenterprise level software solution for collecting,tracking and communicating real-time equipmentperformance and efciency information.

As PBV experiences the success of WonderwarePerformance Software at the Garner, North Carolinafacility, theyll be able to capitalize on this successand roll it out into their other plants across thecountry. Pepsi Bottling Ventures has realized higherefciency based on Wonderwares advancedvisualization, easy to use interface and unbeatablereal-time data collection. Success at this level is assweet as the drinks they make.


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Invensys, the Invensys logo, ArchestrA, Avantis, Eurotherm, Foxboro, IMServ, InFusion, SimSci-Esscor, Skelta, Triconex, and Wonderware are trademarks of Invensys plc, its subsidiaries or afliates.All other brands and product names may be the trademarks or service marks of their representative owners.

2013 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, includingphotocopying, recording, broadcasting, or by any information storage and retrieval system, without permission in writing from Invensys Systems, Inc.

Invensys Operations Management 10900 Equity Drive, Houston, TX 77041 Tel: (713) 329-1600 Fax: (713) 329-1700 iom.invensys.com

Rev. 03/13 PN WW-4053
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