PepsiCo - Frito LayData Driven Operational Efficiency

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PepsiCo- Frito Lay PepsiCo products are consumed by more than 200 countries and regions around the world, one billion times a day. PepsiCo’s extensive food and beverage product portfolio includes hundreds of food and beverage products, with 22 retailers each selling over

.$1 billion in a year.r

PROBLEMIn PepsiCo Frito-Lay, there are several manufacturing productions lines therefore

energy is a major operating expense. A corporate-level initiative to reduce overall

Despite best efforts by the engineering team to reduce costs, the team had difficultybenchmarking the plant’s performance over time, adjusting for fluctuations in produc-

tion value. The unit energy cost per unit production of the potato chips package was unknown, therefore the effect of energy saving measures on profitability couldn’t be calculated. Monthly utility bill data only explained how much was due, not what was driving that number. It was very difficult to measure and verify the impact of equipment upgrades/optimization. The performance targets and realization rates were tracked manually, results in labour intensive processes.s

production costs to drive profitability exists, however engineering team lacked vis-ibility and real time intelligence to make better decisions about energy use in different production lines. Additionally, maintenance costs peaks caused by the unexpected

.shutdowns among the important production lines.s

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SOLUTION

RESULT

Better Visibility on Energy Performance

The energy managers and manufacturing engineers decided to use Faradai EnergyIntelligence Platform in their order to monitor energy performance, increase opera-tional efficiency by tracking in their factories production line shutdowns and main- tenance schedule, identify waste and create a base for their industry 4.0 efforts. The platform integrates to the existing metering and ERP system in order to collect both real time production and energy consumption data. Additional sensors and meters .were installed in order to give a better visibility to facilities operations.s

Factory engineering team is able to see when equipment costs more to run than they initially expected. When they see something strange come up in their energy profile, they are able to change their operations to save energy. They are able to benchmark different production lines according to their energy intensity. “It’s really nice to see when we upgrade a piece of equipment how our energy profile changed from month to month—we can see when we do an upgrade what effect it actually has over our

.energy usage. ” e

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Higher Operational EfficiencyHigher Operational Efficiency

The team had specific KPI tracking tools based on excel spreadsheets before. Afterutilizing Faradai Energy Intelligence Platform, the performance metrics are automati-

cally calculated and reported. Engineers were experiencing a high peak at a certain time and they didn’t understand where it was coming from. Utilizing the real time analytics modules of Faradai Energy Intelligence Platform they can detect when theirmanufacturing lines and corresponding air compressors reach a maximum consump-

tion threshold. They can track spikes during the shifts. They are able to pinpoint where the spike is coming from with the cloud software and gain visibility into performance

Proactive Equipment Health Check

At a glance they are able to find out exactly what they are doing at any point in time. Faradai Energy Intelligence Platform gives the team an idea of whether or not we’re staying on course and lets them know when they have issues so they can take action

.immediately.y

They are able to set limits to get alerts for an off shift. They can get emails or texts to notify them when they are running higher than normal or if they left something on and then come in and investigate. They can also set low limits for seven days a week, .so they know if they have lost power.r

Faradai Energy Intelligence Platform monitors and analyses some critical equipmentparameters such as motor temperature and vibration so that some data driven notifi-

cation are pushed to the operators in order to detect critical equipment faults before.they occur and optimize their maintenance schedule.s

.parameters at the plant that they didn’t know about beforehand.d

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Better Sustainability Reporting, Efficient CooperationBetter Sustainability Reporting, Efficient Cooperation

Faradai Energy Intelligence Platform automated and customized reports comethrough email and the team can share those with the management and other stake- holders. Based on the analysis, they can bring questions, like ‘Why are we using less energy now than we were last year?’ And they can look at their production data and see if they are running less equipment or if they have less machine hours. The weekly .and monthly reports are a good trigger for these conversations across the facility.y

Faradai Energy Intelligence Platform gives Mr. Kapici and his team the visibility to make better decisions about energy use, driving down costs, saving his team time, .and providing concrete data about how well the facility is managed.d

We didn’t have a cleat image of what our overall and production line-based energy profile looked like, so it was kind of like being in the dark before we commission the Faradai Energy Intelligence Platform. You really couldn’t see the ups and downs andthe valleys in energy performance and determine what was going on. It was frustrat-.ing not knowing if you had any waste.e

Olcay Kapici, Maintenance Manager

Faradai1 Mark Square, Hackney London, EC2A 4EG

P: +44 7552 487 007

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Formerly Reengen