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Case study
Cutting unplanned stops on a bottling line
A beverage bottling line, from fermentation to palletising, where a stopped machine only showed once product was already piling up behind it.
A representative scenario, built from the problems we see most often in this kind of site. Exact figures vary from one installation to another.
Starting point
The line has twelve stations, from fermentation to dispatch, with one operator per shift walking the floor. Stops were logged from memory, at the end of the shift.
Main problem
An empty cap feeder or an abnormal motor vibration were only noticed once bottles stopped coming out, and the reason for the stop rarely made it cleanly into the report.
Solution put in place
Vibration, temperature and count sensors on every station feed COA Linha. The screen shows the whole line's status, the operator gets the alert before bottles pile up, and every stop is logged with its cause.
Key results
Compared with the earlier manual log:
time lost to unidentified stops
line OEE
of stops logged with a cause
Day to day
What the team sees on screen
COA Linha — Estado da linhaView of the full line, with each station's status and the shift's history.
Estação 9 — FichaA station's record: vibration, temperature, rate and an open maintenance order.
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