Rapid Product Change Over – FMGC (Fast Moving Consumer Goods)
TASK: AUTOMATE CONTROL SYSTEMS
Through the successful implementation of a new Rapid Product Change Over (RPCO) system, production efficiency was increased for a Personal Care Manufacturing Plant. Our team member was responsible for the complete integration of engineering, including the development of a new URD (User Requirement Document), and the design and installation of software to streamline brand change processes. By extracting the operation philosophy from the running logic and optimizing the software design basis, the brand changeover time was reduced from 45 minutes to just 12 minutes on average, enabling the plant to perform two brand changes daily and reduce downtime by approximately 30 minutes per production order change. The system also minimized Reblend tank usage and reduced CLP (Regulatory) stops, significantly boosting overall line efficiency. End-to-end solutions were provided, from the Front End Engineering (FEE) phase to system startup, testing, training, and ongoing support to ensure seamless operations and minimal downtime.
