Lifting OEE by 22 points on legacy beverage bottling lines.
OEM-locked legacy bottling equipment was capping throughput. We rebuilt the autonomous maintenance program and changeover discipline.
+22pts
OEE lift
$11M
Annualized savings
63%
Changeover time cut
0
Recordable safety incidents
The starting condition.
Legacy OEM-locked bottling lines were capping throughput at 64% OEE. Capex pressure made replacement infeasible for 24+ months, but throughput shortfalls were already costing $11M annually in lost market opportunity.
What we did,
in order.
- 01
Diagnostic against ISA-95 framework, identifying 18 specific equipment-availability bottlenecks.
- 02
Autonomous maintenance program redesigned for operator ownership of routine PMs.
- 03
SMED-based changeover redesign: 73-minute changeovers compressed to 27 minutes.
- 04
Operator academy: 142 line operators certified across four lines, three shifts.
- 05
Asset performance dashboard built on existing SCADA infrastructure — no new capex required.
What was sustained,
at month twelve.
- +22 percentage points OEE lift, sustained at month 12
- $11M annualized savings from recovered throughput
- 63% changeover time reduction across all four lines
- Zero recordable safety incidents during engagement
- Internal AM/PM program now run by client team without our involvement
Your operation,
your case study.
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