CASE STUDY • LIGGETT VECTOR BRANDS
Improving Operational Efficiency:
Predicting Machine Downtime
NexStratus was engaged to conduct a comprehensive assessment of
Liggett Vector Brand's end-to-end supply chain.
3 min read
8 Million
per manufacturing
line restored
4 Weeks
project
engagement
60% Decrease
in unplanned machine
downtime
Liggett Vector Brands, a high-volume manufacturing and packaging facility, faced significant challenges with frequent unplanned downtime and line stoppages, despite having best-in-class maintenance and control systems. The company recognized the need to enhance its operational efficiency and increase throughput, particularly for its critical production line, Line 612.
BACKGROUND
OBJECTIVE
NexStratus was engaged to conduct a comprehensive assessment of
Liggett Vector Brand's end-to-end supply chain. The objective was to reduce downtime,
maximize mean-time-between-failure (MTBF), and optimize Overall Equipment Effectiveness (OEE) for Line 612.
Data-backed Insights
Using predictive analytics, NexStratus accurately identified opportunity to reduce downtime and maximize mean-time-between-failure (MTBF) on their manufacturing floor.
APPROACH
1
Supply Chain Analysis
NexStratus conducted an in-depth analysis of Liggett Vector Brand's entire supply chain, focusing on identifying bottlenecks, inefficiencies, and areas for improvement in the production process.
2
Dynamic Synchronization
By leveraging advanced data analytics, we developed
strategies to dynamically synchronize machine speeds across Line 612. This approach aimed to balance load, reduce stress on equipment, and enhance overall production stability.
3
Real-time Monitoring and Predictions
Implemented real-time monitoring systems to
provide visibility into machine performance. Informed Insights, our proprietary solution, was deployed to offer real-time optimal speed predictions for both Maker and Packer operations, along with the anticipated effects of each potential change.
4
Failure Probability Analysis
We conducted a comprehensive failure probability analysis to assess the risk of implementing new speed adjustments. This analysis helped in predicting the impact of changes and mitigating potential disruptions.
5
Performance Optimization
We provided targeted recommendations to improve OEE by aligning real-time line and shift conditions with production goals.
Harnessing the power of real-time monitoring, predictive insights, and dynamic synchronization to increase production potential and operational effectiveness.
RESULTS
1
Reduced Downtime
Our strategies to dynamically synchronize machine speeds resulted
in a significant reduction of 60.5% in unplanned downtime. This improvement directly contributed to maximizing the MTBF for Line 612.
2
Enhanced OEE
By optimizing the operational parameters and minimizing downtime, we achieved substantial improvements in Liggett Vector Brand's Overall Equipment Effectiveness. This optimization translated into increased production potential and efficiency.
3
Real-time Predictive Analytics
The implementation of Informed Insights provided Liggett Vector Brands with real-time visibility into optimal machine speeds and the anticipated impact of adjustments. This tool enabled proactive decision-making and continuous improvement.
4
Operational Efficiency
The proactive maintenance and synchronization strategies led to
enhanced operational efficiency across the supply chain, ensuring smoother production processes and higher throughput.
NexStratus's data-driven approach revolutionized Liggett Vector Brand's
supply chain operations, significantly reducing unplanned downtime and enhancing overall efficiency.
By harnessing the power of real-time monitoring, predictive insights, and dynamic synchronization, Liggett Vector Brands achieved substantial improvements in production potential and operational effectiveness, positioning itself for sustained success in the competitive manufacturing landscape.
