Manual record keeping is a thing of the past in Kofola

Present

• In March 2024, the technology upgrade of D2000 and PM Toolkit to the new and current versions was completed.
• The main reason for the system upgrade was the transition to a new database system ensuring higher speed and stability, the possibility of archiving more data coupled with the maintenance and protection of historical data, as well as the improvement of the user interface and functionality of the systems.
• Currently, the system is centrally operated in Kofola plants: Rajecká Lesná (SR), Kláštorná (SR), Karlovarská korunní (CR), Krnov (CR), Ondrášovka (CR), Mnichovo Hradiště (CR), Studenac (HR) and Leros (CR).

Implementation process

• The pilot was carried out at the Rajecká Lesná plant in 2018, followed by a gradual rollout to plants in the Czech Republic, Slovakia and Croatia. The solution is also continuously applied to the Group’s acquisitions.
• All sites access one common server.
• From SAP, information about the order, standard and pieces goes to PMT. The information associated with the specific order goes back to SAP, i.e. j. the units produced, the time consumed; the operators involved in the production; the downtime – its reason, length and number.

Benefits of implemented solutions

• Management has a detailed and actual production status of the lines as well as a detailed history.
• A uniform KPI evaluation methodology is in place for the Group’s businesses.
• Machine signals not only allow monitoring of machine operation, but also automatic definition of downtimes based on the recorded status.
• The realisation of the technical downtime records led to the optimisation of maintenance interventions. A more accurate record of technical downtime has allowed to focus on critical parts of the equipment.
• Real-time logging showed that a significant portion of the downtime was tied to machine setup. Management responded with increased attention to training workers in line setup, and the result was improved efficiency of production equipment.
• Significantly simplified administration in production. Operators can devote the time gained to production.
• Visualisation on LED TVs in production gives workers an overview of all the indicators (KPIs) affecting their monthly bonuses. The visualization displays not only data from PMT, but also set data accessible from SAP.

The visualisation allows the information that needs to be communicated to plant operators to be displayed on the panels in an operational manner.

Customer statement