Food Production · Bakery & Snacks

Changeover Reduction

Pre-stage recipes and benchmark SMED execution to slash changeover time by over a third.

−38%

Changeover Time

From 47-minute average to 29 minutes, equivalent to 1.2 additional production runs per shift

−71%

First-Article Rejects

Pre-staged recipe parameters via MES integration cut startup scrap from 340g to 98g average

+22 pts

Planning Adherence

Schedule adherence improved from 61% to 83% as changeover windows became predictable

How Allie Works Here

From signal to action in real time.

Production PlanningProduction Optimization

The Production Planning agent sequences SKU orders to minimize changeover complexity by grouping similar film widths and seal temperatures. At T-minus 15 minutes before each scheduled changeover, it pushes the next recipe parameters to the Optima CF OPC-UA recipe server, sends a task notification to the operator on shift, and pre-warms the seal bar to the target temperature. The Production Optimization agent monitors changeover execution in real time, comparing elapsed time against the SMED benchmark, and escalates only if the line has not confirmed 'First Article Pass' within the target window.

Machines & Connectivity

OT-connected, protocol-native.

Optima CF Packaging Line

Optima Packaging Group

OPC-UA

Primary flow-wrapping line; recipe parameters define film tension, seal temperature, and dwell time

Mettler-Toledo X37 X-Ray Inspection

Mettler-Toledo

EtherNet/IP

Inline weight and foreign body detection; recipe-specific reject thresholds

Omron NX1P2 PLC

Omron

EtherNet/IP

Coordinates recipe download, tooling unlock, and CIP permissive interlock

Process Variables

The signals Allie monitors and moves.

Signal Name	Historian Tag	Unit	Baseline	Optimized	Target
Changeover Duration	`PACK01.CO.DUR`	min	47	29	Lower
First-Article Inspection Pass Time	`PACK01.FA.PASS`	min	18	8	Lower
Film Tension at Recipe Activation	`PACK01.FLM.TEN`	N	±12%	±3%	Tighter

Changeover DurationLower

PACK01.CO.DUR

Baseline: 47 min→ 29 min

First-Article Inspection Pass TimeLower

PACK01.FA.PASS

Baseline: 18 min→ 8 min

Film Tension at Recipe ActivationTighter

PACK01.FLM.TEN

Baseline: ±12% N→ ±3% N

In the Field

"a multi-SKU snack manufacturer running six packaging lines with an average of 12 SKU changeovers per shift"

Deployed at a multi-SKU snack manufacturer running six packaging lines with an average of 12 SKU changeovers per shift. The results above reflect production data from the 60–90 day period following full deployment.

−38%changeover time

−71%first-article rejects

+22 ptsplanning adherence

Next Step

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