High-Speed Filling & Capping Lines
20%
Reduced investigation time for customer-reported issues.
25%
Improved FAT documentation accuracy and accessibility.
BACKGROUND
A manufacturer of high-speed bottle filling and capping lines faced difficulty maintaining traceability of critical components in customer-specific machines. Each project used different bottle sizes, filling heads, servo systems, sensors, and change parts, making retrieval of complete build and testing history increasingly difficult. The company required a digital solution to ensure full product-level traceability throughout manufacturing and factory acceptance testing (FAT).
CHALLENGE
- Manual tracking for critical components such as servo drives, filling valves, sensors, and motors
- Difficulty identifying the exact component installed in a delivered machine
- Factory Acceptance Test (FAT) records maintained separately from production data
- Customer complaints requiring significant effort to identify affected assemblies
- Limited visibility into component genealogy and machine configuration history
APPROACH
- Implemented Opcenter to create a product-centric traceability framework for bottle filling and capping lines
- Assigned a unique digital build record to each machine serial number
- Captured barcode-based traceability of critical purchased and manufactured component.
- Linked filling heads, capping units, conveyors, sensors, and drives to the machine genealogy
- Connected FAT results, performance validation data, and quality inspections to the same digital record
- Established real-time visibility of machine configuration throughout assembly and testing
