Case Studies Blending the Right Reasons with GainSeeker Suite® to make a Sensible Investment

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	Blending the Right Reasons with GainSeeker Suite® to make a Sensible Investment

Blending the Right Reasons with GainSeeker Suite® to make a Sensible Investment

Technology Category	Analytics & Modeling - Real Time Analytics Functional Applications - Remote Monitoring & Control Systems
Applicable Industries	Consumer Goods Packaging
Applicable Functions	Process Manufacturing Quality Assurance
Use Cases	Predictive Maintenance Process Control & Optimization
Services	Software Design & Engineering Services System Integration
Challenge	The quality manager for a consumer goods packaging company faced a critical issue due to recent automation of the ingredient mixing process. While automation increased first pass yield, line efficiency, and throughput, it eliminated the meticulous records previously kept by inspectors. This posed a challenge in ensuring quality data to support federal regulations, especially for long-term stability of the consumer product. The quality team envisioned software that would automatically collect data from the PLCs controlling the flow meters, providing accurate inspection documentation to satisfy federal regulators in the event of a product recall. Read More
About Customer	Hertzler Systems has been providing seamless, accurate data acquisition solutions for over 30 years. They serve a diverse customer base in service, transactional, and manufacturing environments, including notable companies like Consolidated Biscuit Company, Darden Restaurants, Pactiv Inc., McCormick & Company, and Hormel Foods. Their customers invest in Hertzler's software and services to easily acquire data in any process, analyze it in real-time, and instantly notify process owners of process variations. These capabilities help clients reduce costs, cycle time, errors, and defects, while increasing profitability and customer service. Hertzler Systems' core competencies lie in delivering these data-driven solutions. Read More
Solution	Hertzler Systems provided the GainSeeker Suite, which turned detailed PLC data into actionable intelligence for each fill cycle. This software automatically collected data from the PLCs controlling the three flow meters that fed ingredients into the mix. The real-time data collection allowed key stakeholders to receive immediate alarms if there were changes in the ingredient mix, giving engineers time to proactively prevent problems. The solution also provided accurate inspection documentation that was easily identifiable and retrievable, satisfying federal regulators in the event of a product recall. This automated system ensured that the quality manager had the necessary data to maintain compliance and improve operational efficiency. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Real Time Analytics

Functional Applications - Remote Monitoring & Control Systems

Applicable Industries

Consumer Goods

Packaging

Applicable Functions

Process Manufacturing

Quality Assurance

Use Cases

Predictive Maintenance

Process Control & Optimization

Services

Software Design & Engineering Services

System Integration

Challenge

The quality manager for a consumer goods packaging company faced a critical issue due to recent automation of the ingredient mixing process. While automation increased first pass yield, line efficiency, and throughput, it eliminated the meticulous records previously kept by inspectors. This posed a challenge in ensuring quality data to support federal regulations, especially for long-term stability of the consumer product. The quality team envisioned software that would automatically collect data from the PLCs controlling the flow meters, providing accurate inspection documentation to satisfy federal regulators in the event of a product recall.

About Customer

Hertzler Systems has been providing seamless, accurate data acquisition solutions for over 30 years. They serve a diverse customer base in service, transactional, and manufacturing environments, including notable companies like Consolidated Biscuit Company, Darden Restaurants, Pactiv Inc., McCormick & Company, and Hormel Foods. Their customers invest in Hertzler's software and services to easily acquire data in any process, analyze it in real-time, and instantly notify process owners of process variations. These capabilities help clients reduce costs, cycle time, errors, and defects, while increasing profitability and customer service. Hertzler Systems' core competencies lie in delivering these data-driven solutions.

Solution

Hertzler Systems provided the GainSeeker Suite, which turned detailed PLC data into actionable intelligence for each fill cycle. This software automatically collected data from the PLCs controlling the three flow meters that fed ingredients into the mix. The real-time data collection allowed key stakeholders to receive immediate alarms if there were changes in the ingredient mix, giving engineers time to proactively prevent problems. The solution also provided accurate inspection documentation that was easily identifiable and retrievable, satisfying federal regulators in the event of a product recall. This automated system ensured that the quality manager had the necessary data to maintain compliance and improve operational efficiency.

Impact #1	The automated real-time data collection allowed the quality manager to respond to changes before they became major problems.
Impact #2	The system provided knowledge that helped in planning for repairs before wear and tear caused the production line to go down.
Impact #3	The GainSeeker Suite offered valuable insights over time, giving clues that could be used for preventative maintenance.

Impact #1

The automated real-time data collection allowed the quality manager to respond to changes before they became major problems.

Impact #2

The system provided knowledge that helped in planning for repairs before wear and tear caused the production line to go down.

Impact #3

The GainSeeker Suite offered valuable insights over time, giving clues that could be used for preventative maintenance.

Benefit #1	Increased first pass yield.
Benefit #2	Improved line efficiency (up-time).
Benefit #3	Enhanced throughput.

Benefit #1

Increased first pass yield.

Benefit #2

Improved line efficiency (up-time).

Benefit #3

Enhanced throughput.

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Overview

Blending the Right Reasons with GainSeeker Suite® to make a Sensible Investment

Operational Impact

Quantitative Benefit