In 2020, Olvi, the international drinks manufacturer, increased sales, turnover and operating profit to a new record level for the fifth year in a row. The positive development puts pressure on maintenance. The problem is handled by e.g. using systems more efficiently.

One of the areas for development is the deployment of the Novi CMS extension, which in practice means adding condition monitoring functionalities to the Novi by Pinja maintenance system. The Novi CMS extension, which is now being piloted, is a new solution that is expected to bring clients savings by e.g. improving timeliness, as well as cost and resource efficiency.

Growth requires the implementation of condition and time-based maintenance

When the condition monitor detects a deviation in measurement exceeding the defined limits, it automatically creates a new work card in Novi. In Novi, data can be added to the equipment card, which enables the creation of various alarms and work orders for the equipment.

According to Olvi’s development engineer Joni Lehto, Pinja came up with the cooperation proposal for the pilot. Automatic condition monitoring is a new area for Olvi. The target of the pilot is the high-pressure compressor of the new plastic bottle line introduced in the fall of 2020. The machine produces high pressure for bottle blowing, and is very critical for the production. If the machine malfunctions, bottle production on that line will reduce or stop altogether. According to Lehto, similar breakdowns have caused headaches and days-long production interruptions on the other production line.

The goal of the pilot is to anticipate such unexpected failures and secure production, considering the criticality of the machine, throughout the process, especially during high season. The need for the pilot is the rapid growth in production, where the volume has increased from 150 million liters to 230 million liters in the last five years.

The growth is putting pressure on us to use even more condition- and time-based preventive maintenance. If our normal calendar-based maintenance interval is, for example, six months, we have produced a lot more in the beginning of 2021 than we did five years ago.  At the same time, the machines work even harder. The changes respond to the current situation better and make it possible to perform maintenance proactively.

The measurement data also facilitates the work of the critical equipment supplier, as the readily available data supports future maintenance planning and troubleshooting. The data can reveal to a professional that the calendar-based maintenance plan cannot take into account.

Need to increase production efficiency applies to the entire production technology

At the end of the pilot period, Olvi will evaluate the progress of the development project and, if the results meet expectations, extend the use of Novi CMS to other processes. The need to increase efficiency does not apply to just one machine or compressor, but to the whole production technology. Olvi’s future goal is to rid calendar-based maintenance altogether.

– In a changing world, we must constantly move forward and try to find better solutions for the future. Things are evolving at a tremendous pace, and change must be approached with an open mind.

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