Reducing costs and improving quality are key to getting return on investment (ROI) from any manufacturing quality management program. The beverage manufacturing industry today faces a perfect storm of increasing regulatory oversight and tightening cost constraints. Manufacturers across industries can learn from the best practices that beverage producers use.
Mandate: Save Money, Reduce Overfill, Avoid Recalls
In recent years, beverage manufacturers have faced a variety of mounting obstacles—from the sugar-awareness movement to elevated and changing consumer demands. Sugary drink taxes could nearly cripple some beverage operations. But, by taking proactive action, manufacturers can make operational adjustments that will result in sustainable cost savings and counter the financial impact of both the tax and shifting consumer preferences.
Opportunities for business transformation are most easily found through a Quality Intelligence solution, which can reduce costs and optimize yield, creating a strong advantage in a brutally competitive marketplace.
However, many beverage manufacturers don’t take advantage of these benefits because of the potential cost and resource constraints of deploying new software. This should never stand in the way!
Beyond the fact that modern and cloud-based Quality Intelligence solutions are inherently affordable and won’t overburden IT departments, they also offer manufacturers the ability to generate immense ROI.
Look Beyond Obvious Variation
Reducing overfill is the first way to improve operations, but there are three other key areas that beverage manufacturers should consider when weighing the cost vs. benefits of a Quality Intelligence solution:
Mislabeling Risk Detection: By implementing checks to verify that the correct product is marked with the correct label, manufacturers can reduce risks associated with mislabeling. Avoiding this type of mistake reduces waste and avoids brand-damaging recalls—generating both tangible and intangible ROI.
Blow Molding: Like mislabeled products, defective or nonconforming bottles also end up as scrap or rework. Unfortunately, defective bottles require that production of their associated product be put on hold until the issue is resolved. This slows down throughput, which translates to fewer bottles sold. To prevent these costly glitches, manufacturers must look for opportunities to improve the efficiency of blow molding processes and implement quality checks to optimize use of the produced bottles.
Compliance Risk Detection: With real-time access to quality data, plants can monitor a variety of information that contributes to the overall quality of the product. This includes the pH, air content, and even whether the bottle caps are too tight. By proactively making sure the product is correct before it leaves the manufacturing facility, manufacturers are limiting the risk of market actions/recalls and production delays.
These opportunities generate ROI on a plant level, but there are greater potential savings and new efficiencies for beverage manufacturers from an enterprise perspective. Quality Intelligence solutions enable manufacturers to “roll up” data and view all operations at once, identifying areas for improvement that will positively impact the global organization.
An effective Quality Intelligence solution helps streamline the analysis of quality data by quickly generating reports—saving plants and quality professionals time and money, and helping them meet beverage manufacturers’ rigorous data requirements.
The Right Quality Intelligence Enables Continuous Improvements
Opportunities to uncover ROI are endless, bound only by the data that manufacturers can collect. This not only nullifies the objection that a Quality Intelligence solution is too expensive, but also creates a strong argument to elevate the importance of such a system by pointing to the ways to prevent risk, create new efficiencies, and drive continuous improvements across the enterprise.
Balancing your processes to get ever closer to your target specifications can be tricky…and missing the mark can cost your company a lot. InfinityQS Quality Intelligence solutions can fuel continuous quality improvement and help you realize cost savings, optimize processes, and expand best practices across the enterprise. To learn more, please visit our website.