Integrator

Priestley’s Gourmet Delights (PGD) aimed to address several key challenges with the implementation of their Manufacturing Execution System (MES) modules. Their goals included eliminating inefficiencies such as multiple panes of glass, lack of material traceability, and the absence of production efficiency tracking. Additionally, they sought to replace paper-based quality records, improve the management of dynamic bills of materials, integrate disparate control systems, and enhance inventory accuracy. Manual entry of consumption and production data was also a significant bottleneck.


The biggest benefit from the MES implementation was the creation of a single point of truth and control for all factory operations. By leveraging Ignition and Sepasoft, PGD was able to standardize production processes and data management, ensuring material and lot traceability. This system provided real-time line performance and inventory data, allowing front-line teams to quickly address high-priority performance issues. The end-to-end connectivity from inbound materials to outbound delivery streamlined operations and opened up further opportunities for value enhancement through available data and processes.


The improvements were adopted across all departments by integrating various modules such as ERP for material codes and stock quantity control, warehouse management, dynamic production run picking, mixing, automated and manual production lines, and automated palletizing and dispatch. Each department's specific needs were addressed, leading to cohesive, efficient operations.


Cost savings were realized through increased operational efficiency, reduced manual labor, and improved inventory accuracy. By automating processes and enhancing traceability, PGD minimized waste and optimized resource usage.


Overall Equipment Effectiveness (OEE) was improved through real-time traceability and the automation of production consumption and goods issuing. Data collected included pre-start checklists, material consumption, production counts, and quality control points, which were used for performance analysis, ensuring adherence to standards, and continuous improvement initiatives. This comprehensive MES implementation has positioned PGD to better manage their complex operations and achieve sustained growth.