In 2009, Swire Beverages looked to implement World Class Manufacturing into its production processes. During this time of implementation, its production performance and employee abilities were enhanced; however, despite ongoing improvements, the company encountered ‘bottlenecks’. These involved different issues: from the accuracy of the data collection, and the timeliness of the data transmitted, to the problem-solving efficiency of the software. This meant that the production lines were still not working to their maximum efficiency, and the output was compromised.
In order to solve these performance issues, members of the Swire Beverages team visited the Sidcup Plant of Coca-Cola Enterprises in London, UK, to take part in best practice learning. The plant team introduced their visitors to the LineView system: an automatic, real-time based data acquisition system designed to monitor the entire production line performance. This visit enabled Swire to explore LineView™ in detail and decide that it was the best solution for their needs.
Based on the new system, the production team, production team leader, maintenance technician and critical machine operators all hold an SIC meeting every four hours, investigating the Six Big Losses of the line. The data is then compared to the previous four hours of production line performance and leads operators to take corrective actions.
These regular SIC meetings help to predict problems in advance for the next four hours, in order to avoid any potential issues.
With the LineView™ system, the greatest feeling comes from getting good results and the accuracy of the data. In the past, we sometimes missed the data in our reports, but now we don’t need to worry. The LineView™ system can generate production performance graphics automatically, so we can see the line performance and exactly where the problems are."
The PM Engineer at the site explains
We all know that Preventative Maintenance works are based on the machines’ performance and status. In the past, we obtained the machines’ performance and status by using maintenance technicians and engineers.”
But now LineView™ provides us with accurate data for the machines’ status and performance. It’s just like having a lot of eyes all on the production line.”
These continuous reports provide Swire with all operational status data and parameters for each machine, creating far more effective operations planning.
The reporting system that is integrated into the LineView™ system offers more than 50 different levels of reports, which show the performance trends of each line and help to plan for improvements of the next production stage, as well as providing justification for capital expenditure.
These enhanced reports quickly proved their benefit: the mechanical efficiency of the pilot line has improved by 6% in just two months. The implementation of LineView™ and the routines, have greatly reduced the Blower breakdown and minor downtime periods by an impressive 61%.
The installation of the new LineView™ system has had a great impact on the overall production line efficiency and performance of the Zhengzhou plant.
It’s clear that LineView™ can provide prompt and accurate actionable intelligence and clear performance visualisation. Even general production staff can be engaged with this data acquisition system. Each operator knows how to use it to monitor and control the performance of the line, and ultimately everyone can use it as a tool for success.
The success of the LineView™ pilot in Zhengzhou led to a rapid system rollout across the Swire group.