Cutting Production Time from 10 to 8 Hours for a Leading Food Processing and Packaging Company
A ready-to-eat food packaging company validated data only at end of shift and waited a month for history. iSERV added real-time validation, fast access to history, proactive alerts and predictive maintenance, cutting production time from 10 to 8 hours.
- Client
- Ready-to-eat food packaging and recipe formulation company
- Industry
- Food processing and packaging
- Solution
- ITHENA Smart Service (iSERV)
- Scope
- Real-time data validation, historical data, performance monitoring, alerts
- Headline result
- Production cut from 10 to 8 hours
Three numbers production moved.
Results after iSERV brought the client's production data into real time.
Plant-wide for real-time view
25 screens delivered live KPIs across the plant.
Saved per operator per shift
Operators saved two hours every shift with real-time data.
Annual savings per plant
Shorter production runs delivered measurable dollar savings.
Meet the organization and understand the context behind the transformation.
A global provider of ready-to-eat food packaging solutions and recipe formulation for renowned food brands and defense organizations. To address challenges related to limited real-time visibility, manual data handling, and inconsistent performance tracking, the company partnered with ITHENA to implement the iSERV Smart Service Solution. This innovative platform delivered real-time operational insights, standardized performance monitoring, and predictive maintenance capabilities. As a result, the client reduced production time, improved decision-making, and increased operational profitability, achieving significant time and cost savings across its facilities.
Before iSERV, we were relying on end-of-shift data, manual processes, and delayed reporting that slowed down our ability to respond. With ITHENA’s Smart Service Solution, we gained real-time visibility across the plant, standardized our KPIs, and automated performance tracking. iSERV helped us cut production time from 10 to 8 hours, streamline operations, and achieve significant cost savings.
– Plant Head
Data that arrived at the end of the month.
Validation happened at end of shift, history took a month and KPIs were not standardised.
- Lack of real-time data validation, limited to end-of-shift or day checks
- Delayed access to historical data, only available at the end of the month
- Absence of standardized KPIs, leading to inconsistent performance tracking
- Reliance on manual processes, leading to inefficiencies and increased risk of errors
- Inability to resolve issues in real time or leverage predictive insights
- Manual data consolidation requiring several hours each week
How ITHENA closed the gaps.
ITHENA implemented iSERV, Smart Service solution enabling the customer to be proactive in visualization and eventually tracking the performance of their assets:
Real-Time Data Validation
Implemented data validation in real-time to ensure accurate, timely information for quicker decision-making
Quick Access to Historic Data
Enabled access to historic data within an hour for quicker insights
Performance Monitoring
Standardized KPIs and made them available across all teams for consistent tracking and visibility
Proactive alerts
Deployed alarm-based exception management routines to detect and resolve anomalies in real time
Predictive Maintenance
Delivered AI-driven platform providing real-time and predictive insights for proactive decision-making
From end-of-shift checks to real time.
An illustrative iSERV view: production data validated live, with alerts that cut hours from every run.