FREE copy of the Uptime Elements Implementation Guide once you subscribe to Reliability Weekly

Schneider Electric, the global specialist in energy management, has helped New Belgium Brewing Company dramatically increase production using its Wonderware MES Performance software.

Based in Fort Collins, Co., New Belgium Brewing emphasizes eco-friendly production practices, continuous improvement and metrics measurement. Just as it is vigilant about the products that go into its premium beers, the brewer also believes it is vital to have and maintain production processes that are as accurate, green and lean as possible.

After a closer look at its bottling lines, the brewer’s operations management team realized they were producing 150,000 cases of beer each week on lines that were capable of producing 294,000. Scheduled and unscheduled downtime was causing valuable packaging time to be lost.

“After ramping up our bottling line to meet growing customer demand, we were disappointed to find the brewery was producing only about half of what it was truly capable of producing,” said Joe Herrick, packaging systems manager, New Belgium Brewing. “Our brewery’s existing manual systems generated a huge amount of data but we had no way of presenting it in context.”

To address these issues and to otherwise improve performance, New Belgium Brewing, with technical assistance from Apex Manufacturing Solutions, implemented a solution using Wonderware manufacturing execution system software from Schneider Electric. Not only does the Wonderware MES software track and record the bottling process automatically, it transforms raw data into user-friendly presentations that drive improvement. For example, the software facilitates shift changes by providing new workers with data on the performance of the previous shift. The system also integrates with the brewery’s existing Wonderware System Platform and Wonderware HMI software. The combined solutions improved operators’ ability to maintain precise packaging production schedules and effectively manage the materials supply chain during the brewing process.

“The ability to customize the graphics provided by the Wonderware MES software solution enabled us to develop a system that could effectively communicate the line status and production capacities of the bottling and packaging lines, while at the same time illustrate New Belgium’s unique company culture with engaging graphics,” said Sam Vail, chief strategy officer at Apex. “Screen data shows what order is being worked on, what is coming next and how the current rate compares to their standard. This is a great example of how Wonderware software changed the game for New Belgium Brewing, effectively enabling them to increase capacity, expand production and improve quality without investing in new equipment.”

“With Wonderware MES Performance software coupled with our continuous improvement strategy, we have increased the efficiency of our packaging line by 30 percent, which allowed us to extend our packaging capacity to about 1.3 million barrels each year,” Herrick said. “Improved manufacturing efficiencies plus increased line production means we’ve saved more than $400,000 in previously planned labor costs and decreased downtime by 50 percent. At this point, our approach to higher volumes is ‘bring it on.’”

About Schneider Electric
As a global specialist in energy management with operations in more than 100 countries, Schneider Electric offers integrated solutions across multiple market segments, including leadership positions in Utilities & Infrastructure, Industries & Machines Manufacturers, Non-residential Buildings, Data Centers & Networks and in Residential. Focused on making energy safe, reliable, efficient, productive and green, the company’s 150,000 plus employees achieved sales of 31 billion US dollars in 2013, through an active commitment to help individuals and organizations make the most of their energy.

Upcoming Events

August 8 - August 10, 2023

Maximo World 2023

View all Events
banner
80% of Reliabilityweb.com newsletter subscribers report finding something used to improve their jobs on a regular basis.
Subscribers get exclusive content. Just released...MRO Best Practices Special Report - a $399 value!
DOWNLOAD NOW
Defect Elimination in the context of Uptime Elements

Defect Elimination means a lot of things to a lot of people. Uptime Elements offers a specific context for defect elimination [DE] as a success factor on the reliability journey [RJ].

Internet of Things Vendors Disrupting the Asset Condition Management Domain at IMC-2022

Internet of Things Vendors Disrupting the Asset Condition Management Domain at IMC-2022 The 36th International Maintenance Conference collocated with the RELIABILITY 4.0 Digital Transformation Conference [East]

Asset Management Technology

The aim of the Asset Management technology domain is to assure that IT/OT systems are focused on creating the value from the assets and that the business can deliver to achieve organizational objectives as informed by risk.

TRIRIGAWORLD AWARDS at MaximoWorld 2022

TRIRIGAWORLD AWARDS honors excellence in space optimization and facility management, A Reliabilityweb.com event to further advance asset management

IMC-2022 Who's Who: The World's Best Run Companies

The International Maintenance Conference (IMC) provides a fresh, positive community-based curated experience to gain knowledge and a positive perspective for advancing reliability and asset management through people, their managers, the strategy, the processes, the data and the technology. The world’s best-run companies are connecting the workforce, management, assets and data to automate asset knowledge that can be leveraged for huge beneficial decisions.

Uptime Elements Root Cause Analysis

Root Cause Analysis is a problem solving method. Professionals who are competent in Root Cause Analysis for problem solving are in high demand.

Reliability Risk Meter

The asset is not concerned with the management decision. The asset responds to physics

Why Reliability Leadership?

If you do not manage reliability culture, it manages you, and you may not even be aware of the extent to which this is happening!

Asset Condition Management versus Asset Health Index

Confusion abounds in language. Have you thought through the constraints of using the language of Asset Health?

Seven Chakras of Asset Management by Terrence O'Hanlon

The seven major asset management chakras run cross-functionally from the specification and design of assets through the asset lifecycle to the decommissioning and disposal of the asset connected through technology