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Find out how AVEVA customers are putting industrial intelligence to work
- Henkel
- Pfizer
- Maple Leaf Foods
When saving becomes leading
Henkel, a global FMCG manufacturer, is a pioneer, reimagining and improving life today and for generations to come. This spirit led to the digital transformation of their Laundry & Home Care division to drive greater efficiency, and thereby greater sustainability.
Goals included reducing specific energy consumption, achieving ISO 50001 certification, and improving supply-chain resource efficiency by 5–6% annually, all the while maintaining growth.
However, Henkel’s challenges in data collection and communication across the supply chain would make attaining its goals difficult. A partnership with AVEVA led to an effective solution.
We adopted a digital backbone as this facilitates a vertical approach. It’s faster and ensures application roll-out quickly generates tangible business benefits.
An elegant device-agnostic solution
Henkel uses AVEVA software to enable its teams to capture and contextualize operational data, manage domain, database, application programs. Device integration is configured independently, without affecting the architecture. Engineers can seamlessly incorporate legacy hardware.
Teams installed more than 4,000 physical and virtual sensors, and more than one million data points are captured every day. Touch-screen devices instantly consolidate and contextualize relevant data, enabling operators to collaborate in real-time and identify problematic areas.
Now, operators can accurately measure energy use across the entire factory. They analyze results within meaningful parameters, empowering teams to take corrective action and reduce energy consumption.
AVEVA’s software delivers overall equipment efficiency (OEE) data that further increases productivity. Machine downtime information enables operators to target in-line improvements.
Payback and then some
Energy consumption decreased by 16% in 2020, leading to €8 million in annual savings and €37 million saved to date. The project achieved full payback within four years and quadrupled ROI after eight years.
Other benefits include a 15% improvement in overall equipment effectiveness (OEE), reduction of filling line waste and 100% label quality rate.
By putting industrial intelligence to work, Henkel transformed its Laundry & Home Care operations, driving sustainability and efficiency across its value chain.
Once we’d implemented the AVEVA-based EMS solution, the energy saved was equivalent to the capacity needed to support the three million inhabitants of Amsterdam and Vienna
When timesaving becomes lifesaving
Pfizer relentlessly pursues breakthroughs that change patients’ lives, and its teams drive innovation to make the world a healthier place. This dedication shone brightest when the call came for the COVID-19 vaccine.
With the world waiting, Pfizer embarked on compressing the vaccine development timeline from nine years to nine months. Achieving this required re-invention and feats of innovation in science as well as data management and process optimization.
Having already embarked on a digital transformation journey with AVEVA, Pfizer understood the transformative potential of standardized and centralized data management to unlock benefits throughout its value chain.
When COVID-19 emerged, Pfizer swiftly leveraged these established practices to accelerate the vaccine project, recognizing the pivotal role of AVEVA software in this endeavor.
We were convinced that science would win, and how data and the AVEVA PI System would be an important part of that victory.
Innovating at the speed of light
Pfizer streamlines operations, facilitates collaboration, and accelerates decision-making across its network by centralizing and standardizing data collection and analysis.
The AVEVA PI System serves as the cornerstone of Pfizer's Global Historian Program, providing real-time, full data visibility and control over its manufacturing processes.
This optimizes Pfizer’s operations, supports the transfer and sharing of data, empowers collaboration between different sites, and enables rapid adaptability.
The data foundation enabled by the AVEVA PI system allows for the monitoring of critical parameters, such as temperature control in freezer farms, mRNA concentration in vaccine batches, and production scheduling for capacity modeling and the removal of bottlenecks.
Additionally, Pfizer’s team can gather insights on process performance, identify areas for improvement, and ensure batch quality and compliance with regulatory standards.
Leveraging the scalability and flexibility of AVEVA’s software, Pfizer exceeded expectations and delivered an unprecedented 3.2 billion doses of the vaccine by the end of 2021.
Transforming medicine manufacturing
By putting industrial intelligence to work, Pfizer maximizes the benefits of advanced data management and analytics.
Harnessing data to accelerate vaccine development has the potential to save millions and restore hope during global crises.
And centralizing data, standardizing processes, and leveraging predictive analytics can streamline operations, reduce time-to-market, and improve the efficacy and safety of medications.
By bringing it up to the global historian, and structuring it in a consistent fashion, suddenly we were able to leverage our SMEs throughout the world.
When real-time data becomes real-life returns
Aiming to become the earth’s most sustainable food company is a huge goal. So it’s appropriate that Maple Leaf Foods thinks big and is on a purposeful journey to Raise the Good in Food.
The flagship plant for the sustainable and digital protein company is a purpose-built facility with the latest technology and practices, including AVEVA’s Manufacturing Execution System (MES).
AVEVA´s MES drives operational intelligence and provides process information and full manufacturing context along with integration between SAP and the machines.
Maple Leaf knew significant yield improvements, waste reductions, and margin gains were possible if the company addressed variations in product dimensions, cooking processes, and slicing parameters.
So, Maple Leaf took the next step to explore the maximum value of the data and available manufacturing execution context to leverage AI.
AVEVA MES was part of the original build. It’s full end-to-end, integral to the operation, responsible for complete integration and tracking all production.
Exploring industrial data to achieve maximum efficiency
To prepare for AI, Maple Leaf further supplemented the existing MES model with the integration of additional IoT sensors to refine the real-time operations context.
The combined MES plus real-time IoT data was then optimized to create the AI and advanced analytics models, establishing a robust continuous improvement process to boost production yield.
Through close collaboration with end users, user-friendly interfaces were developed to ensure operational team buy-in driving successful adoption of the new AI application. The enhanced visibility empowered operators to make better decisions and respond proactively.
The outcomes were noteworthy.
Optimized cooking recipes and processes led to lower energy consumption and fewer out-of-spec products. Material waste and losses were reduced.
And golden batches with precise slicing parameters have been established using AI models, leading to improved yields.
As a result, Maple Leaf Foods reported a minimum 10–12% increase in gross profit.
Don’t reinvent the wheel
By putting industrial intelligence to work, Maple Leaf exemplifies how to overcome challenges and achieve goals faster by better utilizing existing software and technology infrastructure.
The core benefits of AVEVA’s software – easy customization to address specific needs and flexibility to integrate with other solution providers – enable Maple Leaf to save time and money on implementation, eliminating the need for extra infrastructure.
ROI on this project was originally…we thought a year. It was three months.
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