Optimization of the CIP, the starts and the ramp-ups of packaging lines

Abstract

The old packaging lines JB1 and JB3 of the ABInBev plant of Jupille present poor efficiency during the starts occurring after stops of a few hours up to several days. Indeed, the cleaning, starting and ramp-up processes are not optimal and face a lot of technical problems but also important problems of organization and of process operation. There is a need to improve them to gain time and then increase its productivity. This work performs a detailed analysis of the problems encountered during these phases, based on quantitative records and observations on the shop floor. The critical machines are identified and the root causes of the problems are investigated. A set of solutions and action plans are developed to solve the problems. One of the main solutions is an organizational tool, the start document. It contains a chronogram for the CIP and the start of the whole line, the process order for the preparation of the fillers and a ramp-up indicator. Other smaller technical and organizational actions have also been set up on the lines. Finally, results have been recorded to evaluate the global impact of the complete set of solutions that has been developed during the whole duration of this work. The performance indicators reveal an improvement of the start and ramp-up processes of the two lines.