POWER to PepsiCo with EAM deployment in six Western European production plants

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In PepsiCo’s POWER project, MaxGrip provided support at the interface between business, maintenance and IT. The goal was to harmonise the operational processes of the PepsiCo plants in Western Europe, and simultaneously create the tools to manage on asset performance. Due to great cooperation, the project results have been impressive enough to be adopted on a global level.

PepsiCo produces and markets a wide range of foods and beverages adapted to local taste. Despite this diversity, a single vision on sustainable growth links PepsiCo workers around the world. ‘Performance with Purpose’ states that financial success goes hand in hand with social responsibility. The company is reducing its environmental impact through innovations, energy savings, and minimised packaging. The vision has proven successful and PepsiCo is in the DJSI World Index for sustainability year after year.

The POWER project

Long recognised for its economic, environmental and social performance, PepsiCo continues to streamline its operations and supply chain in order to ‘future-proof’ the company. The Performance Optimization Western Europe Region (POWER) project started several years ago. PepsiCo operates six plants with different historical backgrounds in the Netherlands, Belgium and France. Two of those were already using SAP. The POWER project brought SAP to the other four plants, the associated offices, and the entire supply chain. The integration of all operational processes and functions in a single software system will create additional competitive advantages.

Benefits

How we help

  • Providing support at the interface between business, maintenance and IT
  • Harmonizing the operational processes of the PepsiCo plants in Western Europe
  • Creating the tools to manage on asset performance
  • Introducing SAP to six plants, the associated offices, and entire supply chain
  • Integrating all operational processes and functions in a single system
  • Generating high-quality maintenance data
  • Delivering control with a complete maintenance management dashboard
  • Creating a clear picture for all plants in terms of availability, reliability, costs, and maintenance

Collaborative approach

MaxGrip was asked to support the plant maintenance part of POWER. The existing global blueprint for strategic maintenance was the starting point. The PepsiCo maintenance managers in Western Europe, led by Freek Freije and Jan Sinnaeve, succeeded in taking things further and improving the blueprint in ten different areas. The production planning and work preparation process was set up according to the World Class Maintenance standard. Jan Sinnaeve: “MaxGrip adopts a human, collaborative approach. Their thinking is very much from the PepsiCo viewpoint, they try to understand what is important to us. We have described all the core processes at the front end that deliver the right KPIs at the back end.”

High-quality data

Implementing an effective Enterprise Asset Management (EAM) system for multiple sites is  challenging. As well as an IT system, a tool was created that introduced equal control parameters for all plants, and allows for a process of continuous performance improvement. To provide management with control, MaxGrip delivered a complete maintenance management dashboard constructed in SAP BusinessObjects.
Generating high-quality maintenance data is a goal hard to achieve, says Freek Freije. “Not just because of the enormous data volume, but also because of its great complexity. Everything is interconnected. The people at MaxGrip speak the language of the boardroom, but also the language of the work floor. They bring different parties into line without anyone feeling threatened. Thanks to MaxGrip, we have become aware that business decisions taken on the basis of inaccurate data can have disastrous implications. We now have a clear picture for all plants in terms of availability, reliability, costs, scheduled and unscheduled maintenance, and data quality.”