Suntory’s new IoT-enabled bottled water plant cuts troubleshooting time by 90%


The system is implemented at the Suntory Kita-Alps Shinano-no-Mori Water Plant, which manufactures Suntory Tennensui Kita-Alps, a 550ml, 2L bottled water product.

The plant is capable of producing 1,000 bottles per minute. Suntory plans to evaluate this model in Nagano, and possibly expand the model to its nine other beverage factories in Japan.

IoT platformIn addition to this, you need to know more about it.

Together with Hitachi, the IoT system took approximately two years from conceptualizing the design to integrating the system.

The decision to develop a next-generation factory model was driven by Suntory’s goal of increasing the competitiveness of its operations, according to Ryo Takayama, senior general manager of the engineering department of Suntory Beverage and Food Limited Japan.

Using Hitachi’s Lumada solution, it can quickly collect, connect and integrate data from the plant’s production facilities and equipment, as well as IT systems for procurement, production, quality management and manufacturing. shipping.

The type of data collected includes machine information, process data, alarm history, run stop information, operational and QC results.

Previously, most of the plant’s operational data, whether collected by machine or by man, was not connected to the entire plant system. This meant limited and missing information.

We estimated that the traceability time to find the cause of the problem and identify the range of defective products in the warehouse would become less than 1/10 compared to the current system, if we find a defective product in the regular quality control»Said Takayama FoodNavigator-Asia.

Using the collected information, performance indicators such as machine efficiency, water consumption, energy consumption, maintenance performance, can be generated and reported to enable constant improvements in quality.

In addition, it also enables faster response when receiving inquiries from consumers regarding the products.

New normal working styleIn addition to this, you need to know more about it.

Beyond saving time and improving quality, the new IoT system also enables remote working.

The COVID-19 pandemic has changed working styles, from restricting the number of employees in the factory to ensure their safety, to transforming factory management and work through digital technology.

According to Takayama, “There was still a lot of human-intensive routine work within the factory, including reporting and collecting and processing the data needed to respond to inquiries.. “

The new IoT platform will complement the changing working styles.

Software has been installed on the dashboard that allows the visualization and analysis of the information required when necessary for different purposes depending on the data of the production facilities and equipment and the plant’s IT systems,In addition to this, you need to know more about it.

And it has become possible to promote remote working and improve work efficiency by digitizing and automating routine, previously human-intensive data collection and processing work.. “


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