PacWest Wonderware pacwest.wonderware.com introduces 'Impact Drivers' and Helps Bottling Plant to Decrease Downtime and Save Money

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Pepsi Bottling Ventures of Idaho, with total payback for investment of less than one year & annualized savings calculated at over $78,500.00.

Wonderware PacWest http://www.pacwest.wonderware.com announces food and beverage industry success story with Pepsi Bottling. In the consumer marketplace, constantly changing tastes drive innovation. This principle plays out- literally - in the beverage business, where offering a multitude of soft drink choices is a mainstay of growth and success. Pepsi Bottling Ventures PBV manufactures and distributes more than 100 different flavors and brands. In 2009, Beverage Industry magazine named PBV its' Bottler of the Year. The company has become the third largest manufacturer and distributor of Pepsi-Cola products in North America, operating 27 bottling and distribution facilities in six states.

In Idaho, PBV runs a state of the art manufacturing and sales distributions plant in Nampa as well as three other distribution centers throughout the state And even as a new member of the PBV family, joining in early 2009, this division has contributed to the company's award winning operations with impressive performance and results.

Integrating the present with the future. "With more detailed data available from the PLC's in Realtime, we are able to cost-justify upgrade projects specifically for certain machine centers. We're able to prove the need for more capital investment." says Chris Bacon, Project Manager for Pepsi Bottling Venture of Idaho.

The Nampa facility was built in 2005 and was equipped with a combination of new and legacy machinery. Blending these assets proved possible, but issues of waste and downtime were apparent.

Additionally, a home grown data collection system that had been in place for the legacy assets did not take full advantage of the capabilities of the new equipment. Operators tracked downtime and recorded it manually during their shifts. Relying on these clipboard notes sometimes led to inconsistent decision making and an inability to track trends accurately over time.

But, PBV didn't accept this situation for long. They knew that better solutions were available. Their vision included a performance management and downtime tracking system that would connect all of the equipment, and that would also help them quantify return on investment and justify future upgrades.

Wonderware Certified Systems Integrator APEX Manufacturing Solutions worked with Wonderware PacWest to assist PVB in evaluating the possibilities. It became clear that Wonderware software was the preferred solution when APEX Senior Project Manager Erik Phillips recommended it, and Chris Bacon, PBV Production Manager, confirmed prior position experiences with the Wonderware Solution. The solution - featuring the Wonderware System Platform, Wonderware Performance software, Wonderware In Touch HMI, Wonderware ActiveFactory and Historian software - was installed in September of 2008, and commissioned and validated just one month later. Introducing Wonderware and APEX "Impact Drivers."

Goals: Improve changeover performance by accurately identifying constraints and bottlenecks. Facilitate better decision making for cross-functional teams through consistent and reliable data which would eliminate guesswork and assumptions. Understand payback metrics and use this data to justify future projects requiring capital investment.

Results: Reports and trending capabilities of Wonderware solution enabled cross-functional teams to review performance data in consistent, reliable and easily shared formats. Cause of downtime in changeover process identified, leading to 50% reduction in changeover time and additional savings in raw materials and packaging. Plant has achieved an overall 10% increase in line efficiency. Total payback for investment took less than one year; annualized savings calculated at over $78,500.00

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Jody Montague
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