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A manufacturing facility was struggling withfilling line inefficiencies, despite seemingly stable monthly performancereports. Frequent, untracked short stops and unclear performance fluctuationswere silently eroding productivity.
By leveraging MontBlancAI’s advancedproduction monitoring tools, the facility uncovered and addressed these issues,delivering a remarkable 12.4% increase in Overall Equipment Effectiveness (OEE)within just six weeks. This case study details the challenge, the innovativeapproach, and the eventual results.
The operations team was aware of the criticalimportance of the filling machine to the facility's production process. So whenthe team uncovered persistent and serious operational flaws, they realized thatswift, decisive action was essential.
The initial assessment and analysis revealedthat multiple brief, unrecorded interruptions were disrupting operationsdaily.
Output inconsistencies lacked clear causes,hampering optimization efforts.
Short disruptions were neither tracked norclassified, masking their impact on efficiency.
These hidden inefficiencies stifled thefacility’s productivity and profitability. Only a comprehensive, data-drivensolution using intelligent manufacturing tools would deliver the desiredresults.
To address the filling line inefficiencies,the facility used MontBlancAI to create and deploy a comprehensive optimizationstrategy, focusing on improving the system’s performance. Key stepsincluded:
The facility seamlessly connected to thefilling machine’s PLC data without interrupting existing controls to gatherreal-time performance insights.
The team identified that the line rarelyoperated for long without short-term interruptions, revealing hiddenbottlenecks that monthly reports overlooked.
Daily, weekly, batch, and order-levelvisualization and analysis were implemented, empowering the facility withactionable performance insights.
In just six weeks, the team—using ourproduction optimization software—delivered a remarkable transformation for thefilling machine’s performance. Put simply, our AI-powered intelligentmanufacturing solution delivered a 12.4% increase in Overall EquipmentEffectiveness (OEE) through significant improvements to availability,performance, and quality.
By eliminating frequent, untracked shortstops, the facility stabilized operations, enabling smoother, more consistentproduction runs. This surge in efficiency boosted output, reduced operationalcosts, and unlocked new capacity.
The facility’s work with the filling machinerevealed powerful insights that drove a 12.4% OEE increase in just six weeks.Three lessons stood out—for both our team and the client.
Our production analytics platform exposeduntracked short stoppages through real-time PLC data analysis. Thisdemonstrated that small, overlooked disruptions can significantly erodeefficiency.
By utilizing daily, weekly, and batch-levelvisualization, MontBlancAI delivered precise interventions that eliminatedperformance inefficiencies and maximized output.
Integration with existing systems minimizeddisruption while delivering big efficiency improvements, showcasing the valueof artificial intelligence in manufacturing.
“MontBlancAI has changed the game for ourorganization. Potential filling machine problems are now identified andrectified before they even have the chance to seriously delay our operations.The entire process has been seamless.” — General Manager
We boosted a filling machine’s OEE by 12.4% injust six weeks, unlocking efficiency and capacity without disruptingoperations.
Our powerful platform can do the same for youroperation with our proven intelligent manufacturing solutions.
Let MontBlancAI’s production monitoringsoftware transform your performance. Contact us today to explore how we candrive similar results for your facility!
Our production analytics platform exposed untracked short stoppages through real-time PLC data analysis. This demonstrated that small, overlooked disruptions can significantly erode efficiency.
By utilizing daily, weekly, and batch-level visualization, MontBlancAI delivered precise interventions that eliminated performance inefficiencies and maximized output.
Integration with existing systems minimized disruption while delivering big efficiency improvements, showcasing the value of artificial intelligence in manufacturing.
We boosted a filling machine’s OEE by 12.4% in just six weeks, unlocking efficiency and capacity without disrupting operations.
Our powerful platform can do the same for your operation with our proven intelligent manufacturing solutions.
Let MontBlancAI’s production monitoring software transform your performance. Contact us today to explore how we can drive similar results for your facility!
