Factbird

Your morning starts with one question: did every site produce what it planned? Lars Sørensen, COO at Crispy Food, Denmark’s largest breakfast cereal manufacturer, runs three sites in Denmark and Poland. Each morning he checks the last 24 hours, the actual OEE of the machines, and planning adherence across all of them. Before, the data behind that came from pen, paper, and Excel. Now it comes in live from the lines. See how Crispy Food keeps one view of production across three sites.

Picture 14 to 15% more throughput from a line you already run. That’s what Snellman, a cold cuts and meat producer in Finland, saw after putting Factbird sensors on a single line. Before, their MES only showed yesterday’s performance as one number. Once the operators could follow the line live, Production Director Ronnie Granlund called the result quite impressive, and the team now expects more on its new lines. See how Snellman got more out of a line it already had.

Changeovers across 12 glass molds can quietly eat the run time you planned. At 200 bottles a minute, Wente Vineyards couldn’t see where downtime happened or how its changeovers really performed, so supply chain had little to schedule the line on. With line data in front of the team every day, they estimate OEE is up 10 to 20% over the last year, and changeovers are improving too. See the downtime and changeover data behind Wente Vineyards’ result.

A line running 200 bottles a minute only pays off if you know where it stops. Wente Vineyards runs 12 glass molds on its bottling line. The team couldn’t see where downtime happened, how changeovers performed, or give supply chain the trends it needed to schedule the line well. Now they review downtime by equipment area with the team every day and use weekly and monthly reports to decide where to focus next. See how Wente Vineyards tracks downtime, changeovers, and OEE on a 200-bottle-a-minute line.

The hardest part of any new shop floor tool is getting your operators to use it past the first week. At Duraco, Continuous Improvement Manager Tony Michalski says rolling out Factbird was easy for operators, maintenance technicians, and site managers alike. The system was ready to go on day one, so the team didn’t have to do the heavy lifting to get started. See how Duraco rolled out live line data without fighting the floor for it.

Your roll change time is probably whatever the whiteboard says it is. At Duraco FlexPack in Saint Charles, Illinois, downtime went up on hourly boards, someone photographed them once a day, and pulling a week’s top downtime events meant building a spreadsheet nobody had time for. Production and Quality Manager Tracy Bruntz now sees measured data instead of the team’s best guess, and roll changes became one of the biggest wins. See how Duraco replaced whiteboard estimates with real downtime data.