Digital Plant Management for CPG Manufacturers

The Dynamic Solution for CPG Manufacturers

Plant-wide visibility that informs an agile manufacturing system and lowers total cost to serve.  

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Digital Plant Management For CPG

Consumer Packaged Goods (CPG) manufacturers operate in a competitive build-anywhere, sell-anywhere market. Move beyond just-in-time supply chain strategies and uninformed capacity planning with plant-wide visibility that drives stable production and consistent product.

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Cost Control

Target areas of waste, minimize supply chain risk, and increase energy efficiency for an improved bottom line.

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Consistent Quality

Maintain superior product standards across multiple lines and SKUs with digitized quality tracking and real-time feedback.

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Optimized Production

Enhance overall equipment and labor effectiveness through better operational workflows, from sourcing to shipment.

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Proactive Compliance

Separate, identify and track the data, documents, and tasks necessary for your unique customer requirements.

Make the Unbelievable Achievable

Maximize Yield
Decrease In Cost Of Poor Quality
within 4 weeks of live data
Increase Productivity
Lift In Line Level Throughput
and over 100% ROI within 90 days
Optimize Labor
Increase In Labor Efficiency
and >$250K impact in 14 weeks

Deliver Quality Products At Lower Cost

  • Tighten Process Controls: Monitor and control critical production parameters, ensuring consistent quality from ingredient mixing and cooking temperatures to assembly line speeds across all SKUs.

  • Fine-Tune Inspection: Track and trend quality check data at various stages to identify non-conformances and reduce defects per million.

  • Reduce Waste: Enable your frontline to identify and rectify inefficiencies in real-time, reducing material excess, product overruns, and energy consumption.

  • Optimize Yield: Maximize product quality and yield with tailored dashboards for analyzing batch data and production trends to reduce waste, energy consumption, and operational costs.

Enhance Operational Visibility and Efficiency

  • Downtime Monitoring: Identify issues impacting productivity, enhance capacity utilization, and reduce disruptions in production by addressing downtime events and unplanned maintenance promptly.

  • Overall Equipment Effectiveness: Track and visualize critical live measures of throughput, availability, and quality within the production process. Accurately assess how efficiently any line or plant is running at any given time.

  • Streamlined Workflow Management: Create dynamic flows that allow for separate operators to complete checks in order and with minimal interruption. Boost productivity in job shops, batch production, assembly lines, and mixed-mode manufacturing environments.

  • Shipment Updates: Understand when timelines are at risk and proactively alert customers well in advance to make necessary adjustments.

  • Customer Satisfaction: Centralize all critical data, enabling a comprehensive view of customer interactions, technical calls, and inbound notes to organize feedback and pinpoint areas for improvement.

  • Customer-Centric Reporting: Generate customized reports and insights that provide your customers with valuable data and analytics.

Ensure Regulatory Compliance

  • Compliance Management: Maintain rigorous compliance across all plant activities, from raw material receipt to final product shipment. Adhere to a comprehensive array of standards and regulations such as USDA, FDA, FTC, and more.

  • Document Control and Audit Readiness: Streamline third-party and internal audits with a centralized digital document management system. Alleviate the burden on Quality by providing auditors secure access to discrete information and historical records.

  • Labeling Accuracy: Manage data from pre-printed items and nutritional labels from each of your SKUs to stay compliant with USDA, FDA, and customer standards.

  • EHS and Sanitation: Fulfill reporting requirements for waste and recycling regulations, and ensure sanitation standards are up-to-date with raw material packaging requirements. 

  • Supplier Management: Streamline supplier communication, capture and track critical documentation, and drive corrective actions while complying with ISO, FDA, and other regulatory standards

  • Risk Management: Oversee the plant’s potential exposure to external risk factors, from suppliers and ingredients, to improve root cause analysis and evaluation of current and future suppliers.

  • Supplier Traceability: Capture all Quality record data for root cause analysis and integrate with existing tools that track logistics for complete supply chain visibility.

Maximize Efficiency Through Integrated Data

  • Automated (IoT) Data Capture: Automate the capture of digital data from equipment, ensuring accurate records of changeover times, energy consumption, and quality metrics to ensure every element of the CPG manufacturing process is measured and managed.

  • Maintenance: Monitor equipment in real-time and leverage data to support Total Effective Equipment Performance (TEEP).

  • Traceability: Quickly unify and associate data and identifiers (such as raw material, batch/lot numbers, etc.) with any process documented by your team during the production cycle.

  • API Library: Exchange data with ERP and MES solutions through flexible APIs that can be coded to various use cases, and ensure consistent data across the plant.

  • Inductive Automation (Ignition): Enable machine data captured by Ignition to drive actions within the SafetyChain platform, automating essential plant processes such as quality checks and live OEE monitoring.

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"SafetyChain Software has helped us digitize all of its processes and give us a birds eye view of how are facility is performing. Being able to be off-site and still see whats going on and whether or not processes are compliant or noncompliant is key to any food safety manager."
Chris G.
Director of Quality, CPG Company
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"SafetyChain allowed our facility to transition from a paper-driven manufacturing operation, to fully electronic record-keeping. Having all operating policies and records housed in an electronic system with statistical capabilities has removed redundancies from our operation."
Erica W.
VP, Quality Operations, CPG Company
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"SafetyChain is our ground truth. It is the record we can always go back to and the working document that our production team uses every single day to make sure we're meeting our quality standards."
Jason M.
VP, Supply Chain

Tips To Stay Competitive And Mitigate Risk

Developing An Effective Supplier Approval Program

Find out how to implement the effective supplier approval with these steps....

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OEE: The Root Cause Analyzer

Determine the root cause for line interruptions, unplanned downtime, quality rejections, and equipme...

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Join The Hundreds Of CPG Companies Who Use SafetyChain On Their Plant Floor

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