Schneider Electric Case Studies The perks of power visibility

	The perks of power visibility Schneider Electric

The perks of power visibility

Schneider Electric

Technology Category	Analytics & Modeling - Real Time Analytics Application Infrastructure & Middleware - Data Exchange & Integration Networks & Connectivity - Network Management & Analysis Software
Applicable Industries	Food & Beverage
Applicable Functions	Discrete Manufacturing Maintenance
Use Cases	Edge Computing & Edge Intelligence Predictive Maintenance Real-Time Location System (RTLS)
Services	Data Science Services System Integration
Challenge	Nestlé Nescafé, the world’s largest soluble coffee factory, faced a significant challenge with unplanned stoppages disrupting production. In one year, the factory experienced eight unplanned stoppages, which had a significant impact on production efficiency and costs. The factory, located in Toluca, Mexico, produces one million jars of coffee every day, and any disruption in the production process can have a significant financial impact. The factory operates 365 days a year, and any unplanned stoppage can impact the reliability of the processes and affect what makes it to grocery shelves. In 2013, Nestlé invested approximately $125 million to expand this plant, increasing production by 40% and making it the largest soluble coffee facility in the world. At this scale, even modest gains to energy efficiency and service improvements translate to sizable cost savings. Improving the reliability of the facility’s electrical equipment would deliver the productivity, efficiency, and maintenance benefits Nestlé sought. Read More
About Customer	Nestlé Nescafé is the world’s largest soluble coffee factory, located in Toluca, Mexico. The factory produces one million jars of coffee every day, making it a significant contributor to Nestlé's overall production. One of the most popular products made at this factory is Nescafé Clásico, a staple for people around the globe. The factory operates 365 days a year, making any unplanned stoppage a significant disruption to the production process and potentially impacting the availability of products on grocery shelves. In 2013, Nestlé invested approximately $125 million to expand this plant, increasing production by 40% and making it the largest soluble coffee facility in the world. At this scale, even modest gains to energy efficiency and service improvements translate to sizable cost savings. Read More
Solution	Nestlé Nescafé turned to Schneider Electric for a solution to their challenge. They implemented Schneider Electric's EcoStruxure Asset Advisor, a solution that allows power systems to be visible and remotely managed 24/7 from any device. The solution was implemented in certain sections of the factory during a pilot phase, with three transformers fitted with PowerLogic Tag Series TH110 wireless temperature sensors, allowing them to communicate with the Asset Advisor service. After a short circuit inside an unmonitored section of the main substation resulted in a 14-hour shutdown, costing Nestlé approximately $588,000, the decision was made to utilize Asset Advisor throughout the Nescafé plant. This gave Nestlé real-time visibility into its electrical equipment, allowing engineers to remotely monitor assets. Prior to Asset Advisor, maintenance was reactive — Nestlé hired specialized service providers as needed. Today, through EcoStruxure, Nestlé has moved to predictive maintenance; connected services anticipate potential failure, which allows teams to resolve issues proactively to avoid downtime. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Real Time Analytics

Application Infrastructure & Middleware - Data Exchange & Integration

Networks & Connectivity - Network Management & Analysis Software

Applicable Industries

Food & Beverage

Applicable Functions

Discrete Manufacturing

Maintenance

Use Cases

Edge Computing & Edge Intelligence

Predictive Maintenance

Real-Time Location System (RTLS)

Services

Data Science Services

System Integration

Challenge

Nestlé Nescafé, the world’s largest soluble coffee factory, faced a significant challenge with unplanned stoppages disrupting production. In one year, the factory experienced eight unplanned stoppages, which had a significant impact on production efficiency and costs. The factory, located in Toluca, Mexico, produces one million jars of coffee every day, and any disruption in the production process can have a significant financial impact. The factory operates 365 days a year, and any unplanned stoppage can impact the reliability of the processes and affect what makes it to grocery shelves. In 2013, Nestlé invested approximately $125 million to expand this plant, increasing production by 40% and making it the largest soluble coffee facility in the world. At this scale, even modest gains to energy efficiency and service improvements translate to sizable cost savings. Improving the reliability of the facility’s electrical equipment would deliver the productivity, efficiency, and maintenance benefits Nestlé sought.

About Customer

Nestlé Nescafé is the world’s largest soluble coffee factory, located in Toluca, Mexico. The factory produces one million jars of coffee every day, making it a significant contributor to Nestlé's overall production. One of the most popular products made at this factory is Nescafé Clásico, a staple for people around the globe. The factory operates 365 days a year, making any unplanned stoppage a significant disruption to the production process and potentially impacting the availability of products on grocery shelves. In 2013, Nestlé invested approximately $125 million to expand this plant, increasing production by 40% and making it the largest soluble coffee facility in the world. At this scale, even modest gains to energy efficiency and service improvements translate to sizable cost savings.

Solution

Nestlé Nescafé turned to Schneider Electric for a solution to their challenge. They implemented Schneider Electric's EcoStruxure Asset Advisor, a solution that allows power systems to be visible and remotely managed 24/7 from any device. The solution was implemented in certain sections of the factory during a pilot phase, with three transformers fitted with PowerLogic Tag Series TH110 wireless temperature sensors, allowing them to communicate with the Asset Advisor service. After a short circuit inside an unmonitored section of the main substation resulted in a 14-hour shutdown, costing Nestlé approximately $588,000, the decision was made to utilize Asset Advisor throughout the Nescafé plant. This gave Nestlé real-time visibility into its electrical equipment, allowing engineers to remotely monitor assets. Prior to Asset Advisor, maintenance was reactive — Nestlé hired specialized service providers as needed. Today, through EcoStruxure, Nestlé has moved to predictive maintenance; connected services anticipate potential failure, which allows teams to resolve issues proactively to avoid downtime.

Impact #1	Improved service continuity and asset health
Impact #2	Reliable, 24/7 remote monitoring of all five electrical substations
Impact #3	Shift from reactive to predictive maintenance, allowing teams to resolve issues proactively to avoid downtime

Impact #1

Improved service continuity and asset health

Impact #2

Reliable, 24/7 remote monitoring of all five electrical substations

Impact #3

Shift from reactive to predictive maintenance, allowing teams to resolve issues proactively to avoid downtime

Benefit #1	Three unplanned stoppages avoided since EcoStruxure’s implementation
Benefit #2	14-hour shutdown avoided, saving approximately $588,000
Benefit #3	Achieved annual target of generating $238 million in factory production

Benefit #1

Three unplanned stoppages avoided since EcoStruxure’s implementation

Benefit #2

14-hour shutdown avoided, saving approximately $588,000

Benefit #3

Achieved annual target of generating $238 million in factory production

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Overview

The perks of power visibility

Operational Impact

Quantitative Benefit