05/24/2022 | News release | Distributed by Public on 05/24/2022 10:27
The world's largest soluble coffee factory, a Nestlé Nescafé plant located in Toluca, Mexico, was looking to eliminate unplanned stoppages and better understand its production efficiency. The factory operates 24 hours a day, year-round, and any stoppage impacts the reliability of production processes. Such interruptions also can affect the quality of the product that makes its way to grocery store shelves. When eight unplanned stoppages in one year caused production to falter, plant stakeholders knew they had to revamp their approach to ensure higher electrical systems resilience and reliability. Nestlé Nescafé chose to partner with Schneider Electric and embark on a transition to a condition-based maintenance approach to address the issue. That meant equipping electrical panels, transformers, and switchgear with sensors and connecting to a cloud-based system that allows the plant floor power assets to be visible and remotely managed 24/7 from any device.
Nestlé Nescafé decided to conduct a pilot to compare uptime differences between connected and non-connected assets to test the proof of concept. As part of their migration to move to a condition-based maintenance approach, Schneider Electric's EcoStruxure Asset Advisor software was implemented, as part of an embedded digital service, to monitor specific areas of the factory during the pilot. Three transformers were fitted with Easergy TH110 wireless temperature sensors, allowing them to communicate with the Asset Advisor platform.
A disruption that occurred in April of 2020 moved the project from pilot to full implementation. A short circuit inside an unmonitored section of the main substation resulted in a 14-hour shutdown, costing Nestlé approximately $588,000. Because this section wasn't connected, engineers weren't alerted that equipment was at risk. This incident catalyzed Nestlé's decision to utilize Asset Advisor throughout its Nescafé plant. Nestlé's investment has already paid off as three unplanned stoppages have been avoided since the new solution was implemented.
Nestlé Nescafé's migration to a condition-based maintenance approach reflects a trend that is rapidly gaining momentum across all industries. Organizations are enriching their traditional calendar-based preventative maintenance plans with more digitized condition-based maintenance implementations. Schneider Electric's EcoStruxure Service Plan, for example, offers organizations that are digitizing their maintenance approach the following benefits:
End users who decide to deploy the Schneider Electric condition-based maintenance approach are provided remote access to a web user interface. This enables a real-time view into reports and performance dashboards that share the electrical assets' performance details. In this way, end users are provided with insights into the current conditions of connected MV and LV equipment, 10-40kVA Three-Phase UPSs, and Variable Speed Drives at the site. This enables technicians to perform the right maintenance at the right time for all their critical assets.
To learn more about the EcoStruxure Service Plan and how condition-based maintenance can lower costs and increase uptime in your plant, download the Nestlé Nescafé case study or visit our web page.