Command Center Case Study

Three team members viewing a PID loop on a TV screen.

A consumer packaged goods client needed to expand production of one of its key product lines but faced significant challenges with material waste and process reliability. Without visibility into the root causes of these issues, expansion was not viable. Interstates partnered with the client to consolidate and analyze data across the production process, helping identify critical inefficiencies and optimize operations through a solution called Command Center. The analytics-driven approach reduced material waste and laid the foundation for scaling the solution across additional facilities. 

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Achieving Real Results

Achieved a 17% reduction in material utilization

Delivered a two-year improvement plan in just 13 months

Enabled expansion of the production line by reducing waste

Solution now being replicated at additional facilities

Challenges

  1. High material waste: Sensitive formulas and raw material variations were causing frustrating and frequent deviations.
  2. Limited traceability: Without consolidated data, the root causes of reliability issues were difficult to identify.
  3. Unplanned downtime: Variations in materials and equipment conditions without knowing where or why they occurred led to extra cleaning, rework, and delays.
  4. Scaling limitations: Extra waste and inefficiencies threatened the viability of the client expanding its productions capabilities.

Solution

Interstates partnered with the client to deliver a data-driven solution that improved reliability and reduced waste without changing or adding hardware. The solution, Command Center, provided an in-depth visualization tool dedicated to specific production lines and a centralized virtual hub, integrating data from multiple sources and formats into a single, user-friendly web application. This platform enables teams to efficiently monitor and manage production, quality, maintenance, logistics, and other critical operations from one unified interface.

Return on Investment

  • 17% reduction in material utilization, exceeding original targets
  • Faster execution, achieving a two-year improvement plan in just 13 months
  • Improved reliability, reducing unplanned downtime and manual intervention
  • Replicability, with the model now being applied to additional business units and sites 

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