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Case Study - sonoco

Optimizing Efficiency for World's Largest Composite Cans Manufacturer

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0 wk

rapid deployment at Sonoco

About the Client

SONOCO is the world’s largest manufacturer of composite cans, tubes, and cores, serving the food and beverage industry. With facilities across North America, Europe, Asia-Pacific, and South America, SONOCO is automating its production lines using Robotic Cells. To achieve its automation goals, SONOCO needed a packaged solution to reduce downtime, increase throughput, and improve OEE by gaining control of its live operational data.
0 wk

rapid deployment at Sonoco

ITHENA’s performance monitoring solution iSERV built on Rockwell Automation’s IoT platform has enabled SONOCO to remotely monitor Robotic Cell performance, track production metrics against planned numbers, and receive detailed Shift performance reports. With its robust data collection and business intelligence suite, the solution has helped identify error patterns, significantly reduced error analysis and resolution time, enhanced operational efficiency, and lowered maintenance resource needs, greatly supporting our automation initiatives.

– Scott Wyatt, Sr. Director – Automation, Reliability, & Machinery Manufacturing

Opportunity for Impact

Rapid deployment
0 -week
Improvement in efficiency of maintenance operations
0 %
Reduction in equipment downtime
0 %

Key Challenges Faced

  • Absence of remote monitoring hindered effective system performance tracking and continuous improvement
  • Lack of a unified platform for real-time insights and alerts, limiting proactive maintenance and decision-making
  • Inability to predict critical equipment KPIs, resulting in higher unplanned downtime
  • Disorganized case logging and task management slowed internal team response times
  • No centralized digital knowledge repository for troubleshooting, extending resolution times
  • Decrease in overall plant productivity and efficiency

Our Solution

ITHENA implemented iSERV solution that enabled the client with:

Performance Monitoring

Real-time visibility into asset performance contributed towards continuous monitoring. Delivered persona-based dashboards for reporting, proactive alerts, and alarms to support maintenance operations

Predictive Maintenance

Digital logbooks and checklists streamlined records. Automated inspections ensured consistent evaluations. Condition & schedule-based maintenance reduced unplanned downtime optimizing the production efficiency

Service Management

Integrated ticketing & case management made it easier to log, and prioritize service requests. Service operations including customer onboarding, technician scheduling & routing were streamlined

Knowledge Portal

From a content hub offering training materials, How-To videos, and mechanics schematics, to the ability to raise service requests through tickets, iSERV offered self-servicing at customer's fingertips

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