Food & Beverage
World-Class Maintenance Practices That Drove Higher Output and Lower Downtime
Transformational Metrics at a Glance
How Proactive Strategies Slashed Costs, Boosted Quality, and Improved Throughput
- Increased packaging line from 12 HL/MH to >50 HL/MH through enhanced asset care.
- Adopted a linear shutdown strategy, fitting 8 hours of maintenance into 4 hours of downtime.
- Revamped asset management, increasing production by 40% and reducing needed lines.
- Cut shrinkage by 40% on a reusable beer bottling line with targeted loss/waste review.
- Reduced CIP chemical use by 15% through pump, instrumentation, and process optimization.
Revamped the company’s asset management programs which contributed to a 40% increase in production levels.
Reduced the use of CIP (Clean in Place) chemicals by 15% through optimization and better care of pumps and instrumentation.
On a reuseable beer bottling line reduced shrinkage by 40% through a loss and waste review.
At a major food and beverage facility, a systematic approach to asset management completely reshaped their production environment. Beginning with the packaging line, the team broke through previous performance barriers—climbing from 12 HL/MH to over 50 HL/MH—by refining maintenance strategies and operational workflows. A key innovation was the introduction of a linear shutdown strategy, where an eight-hour maintenance workload was deftly compressed into a four-hour line outage, significantly reducing downtime without compromising on quality.
We boosted packaging line output from 12 to over 50 HL/MH—while shrinking downtime and costs.
These principles scaled across the operation. Overhauling the company’s asset management programs led to a 40% production increase, enabling them to meet demand with fewer production lines. Improvements weren’t limited to quantity; quality and sustainability saw gains as well. On the reusable beer bottling line, a deep dive into losses and waste trimmed shrinkage by 40%. Meanwhile, optimizing pumps, instrumentation, and cleaning protocols cut CIP chemical use by 15%. To maintain this momentum, SMED (Single-Minute Exchange of Dies) techniques streamlined changeovers, ensuring agility and responsiveness to shifting market needs.
From end to end, this holistic focus on proactive maintenance, lean principles, and thoughtful asset care propelled the facility from ordinary to world-class performance standards.
