Cost reduction and efficiency in the can

Posted on 16 Mar 2014 by The Manufacturer

Coca Cola Enterprises teamed up with Siemens Industry to automate its canning process and boost overall efficiency.

Coca Cola Enterprises (CCE) and Siemens Industry are embarking on a process of standardisation of automation and controls as a result of a recent partnership agreement.

The strategic approach is based on standardisation to support CCE’s drive to increase the production efficiency of its bottling and canning lines; reduce levels of maintenance and training requirements across its production sites; optimise spare part stock and future proof investment in its facilities.

Standardisation of Siemens automation controls at CCE’s Sidcup plant has been implemented as part of the commissioning of a £14.3 million production line newly up and running for canned products.

Noel Corry quote

The new KHS canning line with a capacity of 120.000 cph is one of five new canning lines supplied by KHS to CCE Europe during the past three years. It will increase capacity at the Sidcup plant by another 20 million cases per annum and support future growth.

When building a new plant or line, end users will use several OEMs to supply individual machines to add to the line. This means a multitude of different control systems, components, software and methods of interfacing to the operator and plant. Taking such an approach can lead to three potential issues.

Firstly, numerous control system architectures for machines and interfaces can lead to lower efficiency, as maintenance staff and operators have to work with and be trained on a range of machines.

Secondly, costs are higher because of a substantial spare parts inventory. And finally, because of an inability to network the individual components within the machine or network the machines together, manufacturers are unable to obtain the level of data required in a real time format.

Higher line efficiency, reduced training costs and less capital tied-up in stock of varying spare parts – which also reflects the achievement of the new KHS line – can be achieved through the application of Siemens’ standardisation strategy called Optimised Packaging Line (OPL).

Noel Corry for CCE said: “After we analysed the installed base we came to the conclusion that a standardised approach could help us in many areas such as cost reduction, training and maintenance needs, spare parts and efficiency gains. Coinciding with the need to increase capacity, the move to a standardised approach and the implementation of Siemens’ OPL concept will, I believe, deliver real benefit in the future.”

Mat Campbell for Siemens comments: “OPL and standardisation are highly beneficial for production sites as CCE is finding out. A prime example is the ability to develop a flexible production line more easily. With all the elements of the line networked together it is much simpler to implement changes and respond to market needs.”