Aptean Case Studies Berner Foods Leverages Factory MES to Increase OEE by 68%

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	Berner Foods Leverages Factory MES to Increase OEE by 68% Aptean

Berner Foods Leverages Factory MES to Increase OEE by 68%

Aptean

Technology Category	Functional Applications - Manufacturing Execution Systems (MES)
Applicable Industries	Food & Beverage
Applicable Functions	Discrete Manufacturing Quality Assurance
Use Cases	Manufacturing System Automation Predictive Maintenance
Services	System Integration
Challenge	Berner Foods, a leading supplier of quality food products, was facing several challenges. The company lacked complete information from the shop floor, which prevented them from identifying and addressing root causes of inefficiencies. They were also struggling with capacity constraints, as they were unable to determine the root causes of production inefficiency and capacity constraints. This lack of visibility was restricting their capacity and business growth. Additionally, production personnel were spending hundreds of man-hours every week filling out dozens of forms. Supervisors alone were spending between two and four hours every day on paperwork. Read More
About Customer	Berner Foods is a market-leading supplier of quality food products, including natural cheese, specialty performance cheese, processed cheese and soy beverages. The company offers leading-edge products to the supermarket, drug, mass merchandiser, club, dollar store, specialty food distributor, foodservice and contract manufacturing channels. Its facilities are USDA- and AIB-approved and ISO 9001 certified and meet the demanding standards of virtually every major retailer in North America. Read More
Solution	Berner Foods implemented Factory MES, a manufacturing operations management (MES) system from Aptean. This system offered a short implementation time and a much shorter learning curve and faster time to value than competing options. Factory MES enabled Berner to employ Lean and Six Sigma principles to reduce waste and unlock capacity. The system provided real-time data, enabling the company to make better and more timely decisions. Factory MES also reduced factory floor paperwork by 40 percent, leading to an immediate $30,000 annual labor savings. The system has become a strategic management tool for Berner, providing better access to data for finance, marketing and sales departments. Read More Log in to view content
Contents

Technology Category

Functional Applications - Manufacturing Execution Systems (MES)

Applicable Industries

Food & Beverage

Applicable Functions

Discrete Manufacturing

Quality Assurance

Use Cases

Manufacturing System Automation

Predictive Maintenance

Services

System Integration

Challenge

Berner Foods, a leading supplier of quality food products, was facing several challenges. The company lacked complete information from the shop floor, which prevented them from identifying and addressing root causes of inefficiencies. They were also struggling with capacity constraints, as they were unable to determine the root causes of production inefficiency and capacity constraints. This lack of visibility was restricting their capacity and business growth. Additionally, production personnel were spending hundreds of man-hours every week filling out dozens of forms. Supervisors alone were spending between two and four hours every day on paperwork.

About Customer

Berner Foods is a market-leading supplier of quality food products, including natural cheese, specialty performance cheese, processed cheese and soy beverages. The company offers leading-edge products to the supermarket, drug, mass merchandiser, club, dollar store, specialty food distributor, foodservice and contract manufacturing channels. Its facilities are USDA- and AIB-approved and ISO 9001 certified and meet the demanding standards of virtually every major retailer in North America.

Solution

Berner Foods implemented Factory MES, a manufacturing operations management (MES) system from Aptean. This system offered a short implementation time and a much shorter learning curve and faster time to value than competing options. Factory MES enabled Berner to employ Lean and Six Sigma principles to reduce waste and unlock capacity. The system provided real-time data, enabling the company to make better and more timely decisions. Factory MES also reduced factory floor paperwork by 40 percent, leading to an immediate $30,000 annual labor savings. The system has become a strategic management tool for Berner, providing better access to data for finance, marketing and sales departments.

Impact #1	Factory MES has primarily enabled Berner to employ Lean and Six Sigma principles to reduce waste and unlock capacity.
Impact #2	The system provided real-time data, enabling the company to make better and more timely decisions.
Impact #3	Factory MES also reduced factory floor paperwork by 40 percent, leading to an immediate $30,000 annual labor savings.

Impact #1

Factory MES has primarily enabled Berner to employ Lean and Six Sigma principles to reduce waste and unlock capacity.

Impact #2

The system provided real-time data, enabling the company to make better and more timely decisions.

Impact #3

Factory MES also reduced factory floor paperwork by 40 percent, leading to an immediate $30,000 annual labor savings.

Benefit #1	Throughput improved by 300%
Benefit #2	Increased Overall Equipment Effectiveness (OEE) 68%
Benefit #3	Added $3M in annual revenue without additional capital investments

Benefit #1

Throughput improved by 300%

Benefit #2

Increased Overall Equipment Effectiveness (OEE) 68%

Benefit #3

Added $3M in annual revenue without additional capital investments

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Overview

Berner Foods Leverages Factory MES to Increase OEE by 68%

Operational Impact

Quantitative Benefit