Preventing Downtime in 24/7 FMCG Production: A CASE STUDY
Background
A leading FMCG (Fast Moving Consumer Goods) company in the toilet roll production sector faced a critical challenge that threatened their 24/7 production line. This line relied on an adhesive application cell, a pivotal element in the production process. However, due to unforeseen breakdowns and the unavailability of a spare actuator, the company was operating at risk. To make the issue worse, the existing actuator model was obsolete, making it impossible to order a direct replacement.
The customer had been forced to salvage components from failed units, combining parts from old and new models. This workaround was unsustainable and increased the likelihood of catastrophic downtime. They urgently needed a reliable spare actuator and other mechanical components to ensure continuous production and reduce the risk of machine unplanned downtime.
Challenges
The factory faced a plethora of challenges, mainly obsolete equipment, as the original actuator model was no longer manufactured. This left them with a high risk of unplanned downtime, as without a suitable spare unit, any new breakdown could halt production entirely.
Due to the obsolete parts, the factory was left with complex compatibility issues, as mixing components from different generations of equipment increased the complexity and risk of further failures. This meant a quick solution was needed to prevent a potential production crisis.
Solution
The customer turned to Garry Haines, Linear & Automation Product Manager, known for his expertise in sourcing and supplying industrial components.
To find the best solution possible for the customer, Garry conducted a specification and compatibility analysis to identify the specifications of the obsolete actuator and highlight the differences between the old and new models to ensure compatibility with existing systems.
Beyond the actuator, Acorn’s experts reviewed other elements of the drive chain and identified additional requirements. These included a replacement gearbox and an upgraded coupling to enhance performance and reliability.
ACORN quickly sourced and supplied all necessary components. By collaborating with product specialists, they ensured that each part met or exceeded the latest application requirements.
Results
Thanks to ACORN’s swift intervention and predictive maintenance, the customer now has a complete spare unit, including the actuator, gearbox, and upgraded coupling. They can plan a scheduled maintenance shutdown to replace the old unit, reducing unplanned downtime. The new components’ enhanced specifications provide greater reliability and ensure the production line meets current and future demands.
Conclusion
This case highlights ACORN’s ability to deliver tailored solutions under pressure. By combining technical expertise and a robust supply chain, they resolved a critical issue for the customer, ensuring uninterrupted production in a high-stakes FMCG environment. This proactive maintenance approach not only averted a potential production crisis but also provided the customer with long-term operational resilience and reduced the risk of unplanned downtime
For industries where downtime is not an option, ACORN continues to be a trusted partner in delivering innovative and reliable solutions.