Shaping the Nestle Future Factory
What I Heard (WIH) Series - Nestlevel 2022
Last week Outside In initiated a deep coverage on the Nestle Future-forward here at:
This week, Outside In continues its coverage of the Nestlevel 2022 event hosted by Nestle Global earlier this year (https://nestlevel.vfairs.com/en/#agenda) – with a focus post on how Nestle is shaping its Future Factory. Here we go…
The Engineer Plays an Important Role
An Engineer is at the heart of everything that they do at Nestle: They are custodians of Nestle’s assets with responsibility to utilize their resources optimally today and for generations to come
Release capacity for Growth
Conserve Natural Resources
Innovate with Technology
Enable highly efficient Operations
(Ensure) Full compliance in Safety and Quality
The Engineering Objective for Nestle Future Factory
Build an Engaged, Capable, Digitally-savvy and Resilient Engineering Community that oversees the deployment of the following Solutions globally:
Mobile Asset and Maintenance Management System
Advance Predictive Maintenance Tools
Smart Process Controls Systems
Real-time Energy and Water Usage Monitoring
Digital/Remote Support
Strategy of What They Want to Accomplish
a) Sustainability Commitment: Net Zero CO2 Commitment, Water Reduction, 100% Renewable Electricity, Plastics
b) Diversity & Inclusivity: Build a diverse, skilled and capable engineering Community
c) 300+ Connected Factories: Connected Workers, Process Mastery, Customized Production
d) Pursue Digital in Operations
Focus Areas for the Digital Factory of the Future
IT Infrastructure
Competency Development
Better Connected Employee
Agility (for the younger generation)
Quality, Relevance and Timeliness of Data
The benefits of connected operations are Transparency (complete visibility of the entire process from start to finish), Responsiveness & Resilience (real-time response on planning and execution throughout the Operations), Flexibility (consumer and customer demand changes are rapidly considered) and Connectivity (information is available immediately to everybody).
The drivers of Change are: Connectivity, Intelligence and Flexible Automation
The Future Factory Strategy (in a Picture)
Some of the Exciting Changes Are:
a) Operator Connect Platform
Live Production Data
Quality Data and Checklists
Safety Information
Operating Instructions
How-to Videos and Troubleshooting
Platform for App Integration
Live in 200+ Factories
b) Factory Control Centre
Integration of all Supervisory Systems
Elimination of Manual Processes – Zero Paper
Integration of CCTV Images in Real-time
Cloud Connectivity with real-time Visualization Dashboards
Dynamic Production Scheduling
Remote Expert Support Capabilities
c) Intelligent Machines
Real-time Connectivity to Equipment
Creation of Physics-based Process Models
Integration into a Digital-Twin of the Process
Diagnostic Information for Operators and Technicians
Predictive Maintenance Data
Machine Learning used for Anticipated Error Detection
Advanced Process Control creating high-level of Quality
d) Robotics
Elimination of Manual Repetitive Tasks
Designed as a Digital Twin
Simulated Factory Operation
Concept Proved prior to Build
Installed and Operational
The Digital-Twin Use Cases
Nestle’s plant in Juuka (Finland) is known for producing high-quality gravies, demi-glace, and fonds for chefs and restaurants. For those not well versed in the food industry, these products are all types of sauces used in cooking and plating at restaurants. Producing these high-quality sauces for demanding chefs and restaurants became increasingly difficult as the factory in Juuka grew older, the efficiency of the plant decreased, and the automation become dated as the years went on
Modernizing the old, remotely located plant was a challenge but with help of Siemens’ Digital Enterprise portfolio, including Tecnomatix Plant Simulation, it quickly became a success story for Nestle.
With Siemens’ Digital Enterprise portfolio, the Nestle plant was able to find a complete solution to digitalize and allow the plant to take the next step into their digital transformation. Several digital twins were created to help streamline the project
One digital twin utilizes the performance data that’s collected from the factory’s live operation and can be used to optimize processes and performance. The other digital twin is a digital model of the plant that was used to simulate the material flow in the factory. The use of Siemens Tecnomatix Plant Simulation allows Nestle to model, simulate, optimize, and validate different production scenarios and their processes
Check the Detailed Story of Nestle’s Juuka (Finland) Digital Factory here at: https://new.siemens.com/global/en/markets/food-beverage/references/nestle.html
And the Digital-Twin Use Cases here at:
In Conclusion
Nestle is pursuing a merger of 2 Technology Worlds: Operational Technology + Information Technology. All factories are not built equal or will have the same structure or play the same role for Nestle – Some will be product-focused, others will be high-volume/low-cost production centers. Each factory will have its own attributes & contribution areas
References & Sources:
1) My Notes from the Nestle Nestlevel 2022 Event: https://nestlevel.vfairs.com/en/#agenda
2) Siemens Coverage of Nestle Juuka (Finland) Factory: https://new.siemens.com/global/en/markets/food-beverage/references/nestle.html
3) Nestle Digital Twin Use Cases: https://blogs.sw.siemens.com/tecnomatix/nestle-uses-siemens-software-to-go-from-outdated-to-trendsetting/