Sonoco saved $50,000
in 9 months
Sonoco is a packaging solutions company for food and household products.
With L2L, the Sonoco team has improved:
-> Reduced unplanned downtime events
-> Reduced maintenance costs
-> Improved reliability on source line and downstream production lines
Proactive maintenance with real-time insights
Sonoco implemented L2L’s platform with real-time sensors to monitor equipment health and automatically trigger maintenance before failures occurred.
Before
Sonoco's industrial KBA curing unit fans failed at unpredictable times, causing significant disruptions and often requiring specialized personnel, equipment, and extended line downtime.
Now
By responding to real-time data, we have avoided costly unplanned catastrophic failures. So far, we're happy with the results.
Production line impact management
Equipment failures of Sonoco’s industrial KBA curing unit fans had cascading impacts on production. By identifying issues earlier, the team was able to eliminate production delays.
Before
A single fan failure could impact up to 5 production lines inside the plant and 6 to 7 additional lines outside the plant, creating cascading production delays and losses.
Now
With improved issue detection, maintenance can service fans quickly to avoid failure, improving the reliability of equipment and minimizing the ripple effect of equipment issues.
These ovens support one of the primary processes where we're applying coatings to raw sheets of steel. When one of the fans fails, not only do you lose that coating line, but that line might be supplying 5 lines inside the plant and 6 or 7 lines outside the plant. You might impact 10 or 12 downstream lines as well. That bubble just pushes out, and it's enormous when you're a supply plant like us.
Maintenance resource optimization
Sonoco used L2L in conjunction with real-time sensors to monitor equipment health and automatically trigger maintenance before failures occurred.
Before
Expensive quarterly scans of the fans with specialized vibration equipment were not able to predict failure and did not reduce the fan failure rate, leaving maintenance teams stuck in a reactive model.
Now
Now, fans can be serviced when needed, and maintenance activities are planned and scheduled during appropriate windows, eliminating emergency overtime and allowing for optimal resource allocation. Overall, Sonoco has seen a reduction in fan replacement costs and has been able to avoid expensive line disruptions.
Daily operations management
Sonoco increased transparency on the shop floor with L2L to engage employees and streamline daily operations management.
Before
Identifying daily priorities was challenging and often reactive, and paper-based manual processes meant information was lost and communication was spotty.
Now
Operators can easily submit Dispatches when issues arise, and maintenance technicians can quickly solve issues, all while having the necessary information to quickly resolve downtime events.
L2L probably saves 10-15 minutes an hour, maybe, with just not having to go through and do all your checks over and over again.
Data management
Data on historical and current processes allows employees to quickly identify trends and areas of improvement and see the impact of changes made.
Before
Shift managers had limited visibility into previous shift performance without manual communication.
Now
By starting their day in L2L, supervisors can see what recently occurred, better identify issues, and better prioritize areas of improvement.
I start my day by looking at L2L, and I can look at the whole day, what happened on night shift, what happened on the mid shifts as far as how much time has been lost on any particular item.
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