A dairy producer in Brazil needed to reduce breakdown frequency and improve equipment uptime, so it targeted increases in Production Time Utilisation (PTU) and Line Machine Mechanical Efficiency (LMME). It also aimed to reduce operational costs, including maintenance costs, utilities, packaging material waste, labour costs and freight for urgent spare parts deliveries. Moreover, it wanted to eliminate an average of three unsterility cases per year.
An analysis of operations found that existing maintenance procedures were insufficient, leading to equipment breakdowns. The solution was a Tetra Pak® Plant Care agreement – a long-term maintenance agreement that included several Tetra Pak® Maintenance Services offerings, with the emphasis on Preventive Maintenance. An employee recognition programme was also introduced to enhance productivity.
Production Time Utilisation (PTU) increase: 66% to 92%
Line Machine Mechanical Efficiency (LMME) increase: 75% to 97%
Annual unsterility cases: zero
Packaging material waste decrease: 3.0% to 0.6%
Results sustained, with annual operational cost reduction of18%
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