How Predictive Analytics in Food Industry Increased Uptime of the Production Machines for a Major Canadian Multinational Food and Beverage Manufacturer? 

What You’ll Find in this Case Study:

• Highlights of the Case Study
• Game-Changing Solutions for the Food and Beverage Industry
• Food Predictive Analytics Challenges of the Manufacturer
• Food Predictive Analytics Solutions for the Food and Beverage Industry
• Impact Analysis of Quantzig’s Food Predictive Analytics Solutions
• Key Outcomes of Food Predictive Analytics in the Industry
• A Broad Perspective on the Role of Food Predictive Analytics Solutions in the F&B Industry
• Key Takeaways

Highlights of the Case Study

Game-Changing Solutions for the Food and Beverage Industry

Thefood and beverage industryhad already adopted several Industrial Internet of Things (IIoT) technologies to boost uptime before the COVID-19 pandemic even started. In the food and beverage industry, there has been a significant push towards leveraging advanced technology for predictive maintenance and process optimization. This includes the adoption of various cutting-edge software programs and data analytics methods to enable predictive maintenance and ensure optimal performance in manufacturing processes.

Some of the key technologies and methodologies being employed in this sector include:

1. Predictive Maintenance: Implementing predictive maintenance strategies using connected sensors, tools, and software to remotely monitor equipment condition and reliability.

2. Data Analytics: Utilizing various data analysis methods such as predictive analytics, multivariate data analysis, and point-of-sale data analysis to extract valuable insights from historical and real-time data.

3. Model Predictive Control (MPC): Employing MPC techniques to optimize processes and control systems in real-time based on predictive models.

4. Machine Learning: Leveraging machine learning algorithms to analyze production tracking data, predict demand, identify trends in customer preferences, and optimize supply chain management.

5. Batch Process Optimization: Employing data analytics and predictive modeling to optimize batch processes, ensuring consistent quality and efficiency.

6. Real-time Data Monitoring: Implementing systems for real-time monitoring of critical quality attributes, trace element composition, storage temperatures, and other relevant parameters to ensure product quality and safety.

7. Supply Chain Management: Utilizing predictive analytics and demand forecasting techniques to optimize supply chain operations, including managing stock levels, addressing seasonality of ingredients, and optimizing storage and transportation logistics.

8. Food Fraud Detection: Using data analytics and machine learning algorithms to detect and prevent food fraud by analyzing various data sources for anomalies and discrepancies.

9. Principal Component Analysis (PCA) and Partial Least Squares (PLS): Employing these statistical methods for dimensionality reduction and modeling complex relationships in manufacturing processes.

10. Decision Support Systems: Developing decision support systems that integrate predictive analytics and real-time data monitoring to aid in the decision-making process for optimal production planning and control.

Overall, the integration of advanced technologies and data analytics methods in the food and beverage industry is driving improvements in operational efficiency, product quality, and compliance with regulatory standards. This trend is expected to continue as companies seek to stay competitive amid supply chain challenges and cost-cutting initiatives.

Quantzig offersbig data analytics solutionsto help detect equipment failure and boost productivity.To know more,

The idea of predictive maintenance offers a variety of ways to automate processes and provide services for remote monitoring. Companies in the food and beverage industries use several cutting-edge software programs to enable predictive maintenance. A data historian enables basic time series and historical data analysis to identify the root causes of previous failures, empowering operators to take preventative action to address these problems. Quantzig offers big data analytics solutions to help detect equipment failure and boost productivity.

Food Predictive Analytics Challenges of the Manufacturer

A major Canadian multinational food and beverage manufacturer collaborated with Quantzig to increase the uptime and reliability of its production machines. The client wanted our assistance in developing agile methods to deliver high-quality products, maintain delivery schedules, enhance safety, and reduce maintenance costs. The client approached Quantzig for its AI & predictive analytics solutions in food industry to optimize resource utilization and improve efficiency.Our client was seeking to resolve the following issues that were hampering its operations:

• Inconsistent product quality
• Unscheduled downtime
• Unscheduled equipment maintenance and unplanned repairs
• Missed production timelines
• Ensuring compliance with regulatory standards

Quantzig’s predictive analytics is applied to all types of data sets, including unstructured data and time series, to identify future faults in machinery.The solution is integrated with existing systems to help companies better understand equipment behavior and coordinate maintenance events seamlessly.

Food Predictive Analytics Solutions for the Food and Beverage Industry

Quantzig helped the client by developing a predictive analytics solution to reduce downtime. Machine learning (ML) technologies and data models helped identify patterns in machine failure occurrence, which could be used for prescriptive maintenance. Quantzig’s artificial intelligence solution optimized the entire production process and increased uptime.

Moreover, real-time operational intelligence (RtOI)and predictive analytics solutions enabled the client to stay on top of operations in all its factories. This enabled insights into potential production roadblocks before the impact.Our predictive analysis system implemented the following to drive production efficiency:

• Automatic tracking of production
• Real-time monitoring
• Shortened response time
• Tracked machine performance
• Preventative maintenance
• Asset optimization

Impact Analysis of Quantzig’s Food Predictive Analytics Solutions

Quantzig’s predictive analytics solutions helped the client to unlock the following benefits to improve the lifespan of machinery by implementing predictive maintenance protocols. This also helped bring about a reduction in downtime and thus enabled the client to meet production schedules. It also helped to reduce maintenance costs and minimize raw material wastage and supply chain disruptions arising from unscheduled downtime.

Using Quantzig’s solution, the client could optimize the production process, improve operating efficiency, and implement technologies to reduce downtime and changeover times. This led to long-term benefits such as increased revenue and better customer relationships.

Key Outcomes of Food Predictive Analytics in the Industry

In a food manufacturing setup, unplanned downtime caused by breakdowns can incur staggering financial losses from spoilage of new ingredients. It can also lead to losses resulting from unmet production targets, which can lead to losing customers to the competition. Hence, there is an increased demand from many food and beverage companies to increase uptime by embracing predictive maintenance using IoT-enabled parts or bright parts to repair and replace a part before it fails proactively.

In collaboration with Quantzig, the F&B client could implement systems and protocols that enable predictive maintenance, resulting in increased uptime and improved production efficiency.

A Broad Perspective on the Role of Food Predictive Analytics Solutions in the F&B Industry

Although a cloud-based solution is the end-all-be-all of streamlined and adequate food and beverage manufacturing, it still needs to be monitored for general operation, maintenance, and administrative specifics. A few companies guarantee 99.7% uptime and accessibility in the food and beverage industry; this guarantee only relates to the cloud infrastructure, not the applications or data.

Imbalances or errors in configuration, resource allocation, and databases can cause an ERP solution to malfunction, which is where uptime monitoring excels.Controlling, observing, and improving system operations to prevent downtime is known as uptime monitoring.

Key Takeaways

Quantzig’s Predictive Maintenance Solutions yielded the following benefits for the F&B manufacturer:

• Improved machine lifespan
• Protected against outage and abnormal supply conditions
• Reduction in downtime
• Increased production
• Minimized maintenance costs
• Improved relationship with customers