Coca-Cola talks factory digitisation at Gulfood Manufacturing in Dubai
While Summit delegates heard throughout conference sessions at Gulfood Manufacturing of the need to collect, analyse and utilise data across the entire manufacturing supply chain, global industry leader Coca-Cola revealed how it has invested in digitisation to its advantage.
Amer Hussain, VP, Integrated Supply Chain, Hindustan Coca-Cola, revealed how his plan to automate a bottling plant, based in the Indian state of Gujarat, has had immediate, measurable results in greater efficiency and a reduction of costs – turning the plant into a benchmark for digitisation across the F&B manufacturing sector.
“We are producing 35 million cases a year using two lines and 67 people in the factory,” said Hussain. “Our aim was to be a lean organisation, be a benchmark of productivity and ensure gender diversity in the workplace.”
Digitising the workplace means Hussain and his team have improved the life expectancy of the plant, increased equipment availability, and improved planning and cost optimisation.
“We have gained real-time machine insights and enjoy predictive maintenance and analytics. We have a far more accurate grip on inventory, and have seen an improvement in material yields, with a lean inventory,” said Hussain.
Other benefits enjoyed by the sate-of-the-art factory include real-time energy management, inventory management, stronger and easier management of QSE systems and a holistic view of activity over the fully connected, paperless factory.
The key takeaway from the session was that digitalising operations has resulted in a 30 per cent saving on fixed costs. “This creates a very clear business case for digital transformation,” Hussain, “we are seeing higher volumes at a lower cost.”
But the success came with a caveat. Hussain warned: “In order for a digitisation strategy to succeed, you must have leadership buy-in, and the right team and tools. The benefits only really come in when you have these three things in place.”