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Line Audit

Our line-productivity and eco audits help you identify bottlenecks and inefficiencies along your line in order to make strategic improvements, reduce consumption and optimise your investment plans.

Line productivity audits

Specialised engineers utilise proven measurement tools and make both qualitative and quantitative observations to assess your equipment, layout and surrounding environment. This holistic analysis allows them to suggest a recommended plan for improvement, enhancing any or all of the following:

  • Productivity
  • Flexibility
  • Hygiene
  • Safety
  • Cost efficiency
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Shock Audit

Goal: minimise damage and breakage on containers on your glass and can packaging lines. 

Principle: securing your product quality and integrity through a diagnostic approach to identify precise locations and causes of packaging deterioration across your line.

Method and options:

  • Analysis of line set up and conditions, shock, pressure and rotation (depending on container format) to assess containers impacts and scuffs on conveyors and machines
  • Root-cause analysis of packaging deterioration during line operations

Deliverables:

  • Prioritised action plan detailing shock and pressure severity levels and locations together with associated recommendations
  • Guarantee on shock level after the audit in case of a new machine installation

Your benefits:

  • Achieve quick wins while the audit is being carried out for specific fine-tuning of equipment settings

  • Increase product safety and lower risk of recalls caused by glass fragments or leaking content
  • Enhance packaging appearance free of scratches, marks or dents
  • Secure introduction of lighter packaging
  • Reduce waste, minimise breakage
  • Optimise uptime without broken containers affecting operations
  • Extend lifespan for returnable glass bottles due to fewer collisions

Diagnostic visit

Goal: anticipate failure and production losses

Principle: get a true assessment of your machine through a clear and prioritised report

Method & options:

  • Your equipment is inspected both in production and stopped to prepare overhaul: a deep analysis is done to optimise your planned maintenance
  • Sidel Group experts perform comprehensive monitoring of your equipment

Deliverable: detailed report with recommended operations listed by priorities, estimated costs and possible improvements  

Your benefits:

  • Keep the equipment in optimal condition
  • Secure sustained output across the entire lifecycle
  • Reduce machine downtime
  • Minimise or even avoid production downtime: with routine on-site health checks of your equipment
  • Maintenance-programme structure with a periodic (annual) diagnostic visit
  • Skills transfer with our operators

Technical visit

Goal: quick checks for quick wins

Principle: inspect your equipment and adjust its performance

Method & options:

  • A real-time operational review: quick checks of key parameters with limited time-production stops.
  • Maintenance, production data and customer feedback are tracked and analysed. 

Deliverable: debriefing with a feedback on important and urgent topics

Your benefits:

  • A real-time operational review with minimum production stop
  • Customised maintenance support
  • Benefit from expert advice to better adjust and run your equipment daily
  • Maximise your asset value for improved Return On Investment and Return On Assets
  • Continuosly improve your Total Cost of Ownership
  • Secure sustained output across the entire lifecycle

Spot Audit

Goal: improve line performance and operations

Principle: a targeted approach to optimise your line

Method and options:

  • On-site measurements to check machine and conveyor speeds, line balance, operations
  • Line-performance evaluation
  • Losses identification and impact 
  • MIS evaluation
  • Options: focus on specific operations (changeover, CIP, with among others), shock and pressure registrations 

Deliverable: submission of action plans to improve efficiency and decrease non-productive time

Your benefits:

  • Customised scope to match your needs 
  • Gain a general and clear overview of line performances 
  • Focus on key issues impacting global efficiency and reliability 
  • Know and recognise "where to work" with clear priorities 
  • Consistently measure improvements through the follow-up of a dedicated action plan 
  • Maximise your performance and improve your Total Cost of Ownership

Remote and DV EIT

Goal: targeted approach to optimise your Effeciancy Improvement Tool

Principle: regular (EIT) follow up

Method and options:

  • Evaluation of usage by remote and on-site visits
  • Remote connection to assess on (EIT) data quality, release, with among others
  • Faults accuracy (Identification, checks on line)
  • Usage of comments and/or predefined comment
  • Usage of (EIT) data in the daily control meeting

Deliverable:

  • Clear status of (EIT) data and usage accuracy
  • Propose action plan to correct any data differences
  • Set of upgrades for consideration
  • Training and monitoring of proper (EIT) use

Your benefits

  • Maximise your performance
  • Continuously improve your (TCO)
  • Secure volumes produced
  • Assessment of data and the usage quality
  • Pinpoint all upgrades to be considered to update installation (new equipment, new upgrades, new modules)
  • Integrate (EIT) in the continuous-improvement approach of the site

Desk Audit

Goal: estimate impacts of various line concepts on efficiency 

Principle: a theoretical approach based on layout and documents study 

Method and options: 

  • Data collection and detailed analysis of the line-production parameters: layout, production sheets, maintenance reports, etc.
  • Simulation of variuos scenarios in order to determine line capability

 Deliverable:

  • Detailed list of the strengths and drawbacks of each of the proposed concepts
  • Proposals for optimised alternatives
  • Estimation of potential efficiency gains for each variant

 Your benefits:

  • Confirm the line capability 
  • Understand the impact of various concepts 
  • Optimise the V Graph and buffer times 
  • Understand the impact of the line organisation 
  • Optimise energy consumption 
  • Secure volumes produced 
  • Decide factual data (Leff gains/concept optimisation)

Full Audit

Goal: to optimise the line in relation with output targets, efficiency targets, new SKUs

Principle: an overall diagnostic study in relation to line upgrade projects through audit and simulations

Method and options:

  • On-site measurements to check machine and conveyor speeds, line balance, operations
  • Line-performance evaluation
  • Losses identification and impact 
  • MES evaluation
  • Identification of all losses
  • Options: focus on specific operations (changeover, CIP, with among others), shock and pressure registrations 

Deliverable: Complete action plan including guarantees of efficiency improvement based on simulations done in relation with modifications proposed

Your benefits:

  • General and clear overview of line performance
  • Focus on key issues impacting global efficiency and reliability
  • Know and recognise "where to work’" with clear priorities
  • Consistent, measurable improvement plan followed by actions
  • Guarantees on line-efficiency improvement associated with future projects
  • Clear view of capex to be considered
  • First step of a detailed engineering study
  • Optimise your project 
  • Secure future volumes produced

Packaging Audit

Goal: identify and categorise all issues, determine their origins, and propose solutions to minimise them

Principle: five steps to increase line availability and cost savings

Method and options:

  • Packaging pre-audit
  • Line and current-bottle audit
  • Packaging improvements and feasibility tests based on agreed Options and Upgrades
  • Line tests with pilot cavity
  • Full start-up solutions with Sidel expert assistance

Deliverables:

  • Preform and bottle master plan
  • Optimised line availability and cost-reduction action plan

Your benefits:

  • General and clear overview of shock and pressure issues
  • Single dedicated Sidel team for the project, coaching lab operators to improve line efficiency 
  • 30 years of PET industry expertise 
  • Optimisation with latest innovations
  • Saving on production costs
  • Two grams average reduction of material per bottle 
  • Decrease in blowing pressure and reheating power
  • Savings on logistics costs
  • Decrease in number of preforms and storage costs

Energy Audit

Goal: measure and optimise energy and fluid consumption per unit of production

Principle: survey that combines analysis of performance and environmental footprints

Method and options:

  • On-site measurements to check line performance with readings for water, power and heat consumption
  • Correlation of measurements to identify good levers for optimisation
  • Comparison with the original equipment specifications and with ‘’Best in class’’ values from our databases

Deliverable: proposals for corrective action programs, which are prioritised to optimise equipment consumption levels and potential performance gains

Your benefits:

  • Increase line performance and optimise your energy ratios
  • Get a general and clear overview of the losses on line performance
  • Know and recognise "where to work" with clear priorities 
  • Consistently measure improvements through the follow up of a dedicated action plan 
  • Maximise your performance and improve your Total Cost of Ownership
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