Production optimization creates tangible results
Arla Foods dairy in Gjesing produces a wide range of cheeses including the blue cheese ‘Blå Castello’, which is one of Arla Foods' most successful products both domestically and abroad. The dairy also produces other types of blue cheeses such as red and white soft cheeses. The cheeses are wrapped on a package line that can handle different types of packaging and different types of cheese. The line is 12 years old and was originally supplied and installed by DIS.
- Over the last few years, we have added equipment to the line, as well as the conveyor and the cardboard machines have been expanded and moved around, resulting in the line becoming unmanageable for new operators. Furthermore, the alarm handling was never updated, says Benny Henriksen, Packaging Manager at Arla Foods Gjesing dairy plant.
DIS has contributed with the optimization of the dairy’s PLC program, documentation of the line, the establishment and development of a systematic alarm display system and the implementation of a buffer system. In the start-up of the project, DIS organized a workshop where selected employees from the dairy participated, including managers, operators and maintenance people. At the workshop, Arla Foods employees contributed with knowledge and experience with using the line, creating a solid foundation for DIS, which then were able to develop and implement the "right" improvement and optimization measures.
In order to visualize alarms and provide an overview DIS established a large screen with an Intouch overview picture and alarm display which allows operators to respond and correct errors and problems much faster than before. Several accumulation alerts and other alarms were made, for example an empty label roll alarm, so operators can react promptly and completely avoid a stop on the line.
- Troubleshooting the line has become a lot easier and more manageable. Our cooperation with DIS consultants has worked fine, and involving our own staff in the process worked well, as we ended up taking advantage of their experience and knowledge and create new knowledge, solutions and implementation through DIS. We are now left with an optimized and functional line, that can cope with everyday challenges, explains Benny Henriksen.
DIS’ review of the system has made it more stable and has increased the buffer capacity significantly. The increased output of 5% means that the return of the investment in updating the line is less than two years, which was one of Arla Foods’ goals. In addition to the direct improvements on the line, documentation and the PLC program have become far more manageable, and will result in less time spend on service in the future.