Insight+ OEE Implementation for a Leading Beverage Manufacturer

CLIENT OVERVIEW

A leading beverage producer operating multiple production facilities nationwide partnered with Insight+ to modernize its manufacturing operations. The engagement focused on improving line performance visibility, minimizing unplanned downtime, and enabling data-driven decision-making across bottling and packaging operations.

BUSINESS CHALLENGE

Two production lines lacked the visibility and analytical capabilities needed to support continuous improvement initiatives. Before implementing Insight+, the client faced several critical operational gaps:

Data collection was largely manual and inconsistent
OEE metrics were limited (basic counts, states, downtime categories)
Production losses and root causes were difficult to analyze
Reporting required manual effort and lacked flexibility
No SKU‑level insights for comparing performance across products

The client needed a solution that could standardize performance tracking, automate data collection, and provide powerful visualization across roles—from operators to management.

SOLUTION: Insight+ OEE & PERFORMANCE MANAGEMENT PLATFORM

Actemium deployed Insight+, a scalable OEE and performance platform built on the Ignition industrial framework. This provided an integrated, automated, and configurable ecosystem for real‑time operational monitoring.

Key Capabilities Delivered

1. Automated, High‑Resolution Data Collection

Insight+ was configured to collect both automated machine data and operator input, including:

Machine faults
Machine states
Case counts
Operator‑entered downtime reasons

This high‑quality data pipeline enabled accurate OEE calculation and deeper loss analysis.

2. Customizable Dashboards & Visualization

Insight+ delivered a full visualization experience with:

User‑created dashboards using pre‑built KPI widgets
Filling and packaging overview screens
Supervisor‑focused summaries
Consistent UI via the Insight+ widget library

Dashboards empowered supervisors, operators, engineering, and management with role‑specific insights.

3. Downtime Classification & Loss Tracking

Operators log categorized downtime events directly through Insight+, transforming raw stoppages into structured insights for continuous improvement.

4. SKU Metadata Integration

The system integrated product‑level data including:

SKU targets (rates, speeds)
Product metadata
Automated target population in KPIs based on selected SKU

This enabled accurate performance comparisons across product types.

5. Power BI Reporting Integration

Insight+ exposed production data via SQL queries for advanced reporting, including:

Weekly and monthly OEE
Shift‑based performance
SKU, size, and format comparisons

OUTCOMES & BENEFITS

1. Real‑Time Production Visibility

Supervisors and engineers gained immediate access to performance data, enhancing responsiveness during daily operations.

2. Accurate OEE & Improved Accountability
Automated data capture replaced error‑prone manual processes, improving OEE accuracy and transparency across shifts.

3. Enhanced Operational Reviews
Stakeholders across departments now use standardized dashboards to support morning meetings, performance discussions, and root‑cause analysis.

4. Scalable for Multi‑Facility Deployment
The architecture supports expansion across additional sites and lines, enabling enterprise‑wide standardization.

5. Future‑Ready Platform
Insight+ and Ignition position the client for long‑term digital transformation, supporting expansions into:

Predictive maintenance
Enterprise cloud analytics
Energy monitoring
Integration with ERP/WMS/CMMS systems

RESULTS:

Insight+ provided visibility into recurring faults and the root causes of downtime across multiple production lines. This enabled engineering and operations teams to prioritize the most impactful improvements on each line.

Over a 30‑week period, the following improvements were recorded:

9.3% reduction in total faulted minutes per month
44.9% reduction in blocked minutes
19% reduction in average downtime event duration

By making losses visible and actionable, Insight+ can drive meaningful reductions in downtime and delivers continuous performance improvement across production lines.

CONCLUSION

By implementing Insight+, the client achieved a modernized line performance system that delivers accurate OEE metrics, meaningful downtime insights, flexible visualization, and a scalable path toward enterprise‑wide digital transformation. The collaboration equipped the organization with the tools and data needed to drive continuous improvement and operational excellence.