plus10 Success Stories

Consumer goods

Maximum cost and resource efficiency

The consumer goods industry sector includes the FMCG (fast moving consumer goods) and consumer electronics as well as home appliances and textile products.

The production of consumer goods is strongly demand- and output-oriented as well as cost-oriented. The mass production of consumer goods needs to run on a high level of productivity and technical availability. Fully automated production lines, e.g. for filling and packaging, are just as widespread as rubber and plastic production, e.g. by blow molding, injection molding or extrusion. 

The plus10 tools Shannon® and Darwin actively optimize fully automated consumer goods production operating in a 24/7 mode. Also existing production lines can be equipped with our AI tools (Brownfield integration).

woman infront of shampoo production machine
© 2020 Henkel AG & Co. KGaA. Alle Rechte vorbehalten

Shannon® for Consumer Goods

Shannon®, the operational shopfloor assistance, provides situational problem-solving suggestions for the employees at an automated production line. The tool thus forms a continuously operating optimization control loop based on high-frequency PLC data. Shannon® provides situational contextual and expert knowledge about problems and their solutions mobile in the app at any time for the entire staff on the shopfloor. This significantly reduces downtime (mean-time-to-repair) and the spread of productivity between different shifts.

Benefits of Shannon® for Consumer Goods

  • 5 – 15 % increase OEE due to reducing downtimes (MTTR = Mean time to repair)
  • Increasing cost efficiency by reducing unit costs
  • 10 – 30 % shortening the ramp-up and relocation phase in the global production network
  • Instant problem-solving support by suggesting most-relevant expert knowledge

Darwin for Consumer Goods

Darwin, the Machine Performance Finder, offers several intelligent functions to identify concrete optimization potentials of an automated production line during operation. In this way, it significantly increases the performance level of the machines.

Darwin Machine Benchmark continuously generates technical recommendations for reducing the cycle time. This also provides maintenance with an early warning system at the function or component level to prevent unplanned machine failures and to always operate each machine at its optimum.

Darwin Bottleneck Detector continuously detects the bottleneck in a linked production line at station level during operation and thus provides relevant information for effective optimization at the bottleneck.

Darwin supports productivity optimization in the field of consumer goods by optimizing the cycle times of cyclic production machines, like injection moulding or extrusion in e.g. white appliance production or e.g. in household products production.

Benefits of Darwin for Consumer Goods

  • Increase in output per time per machine by reducing the cycle time
  • Identification of performance potential regarding cycle time and transparency for production planning
  • Early warning system before breakdowns happen
  • Maintenance and production optimization can be effectively scheduled

Success story: Darwin at Vileda/Freudenberg

Injection Moulding 4.0: High frequency data collection and mapping of several data sources at Vileda


Conception and realization of a high frequency big data infrastructure and data mapping for injection moulding machines as an enabler for subsequent machine learning modules. 

Bucket production at Vileda/Freudenberg
© Freudenberg Home & Cleaning Solutions GmbH

Implementation of several data interfaces to each controller

  • Connection and data mapping of sensors for raw material characterization
  • DEMAG injection moulding machines
  • In-mould sensors measuring temperature and humidity
  • Handling devices and buffering systems for produced parts
  • Quality station for individual quality checks of each part
  • Creation of a virtual buffer system to track and trace individual parts after injection moulding
Portrait of a man

plus10 established a high-frequency data infrastructure for our injection moulding machines. The collaboration also included a virtual component tracking system to continuously and automatically link all process and subsequent quality data to a product. I was very impressed by the expertise and reliability of plus10.

Uwe Dingert

Director R&D, Freudenberg Home and Cleaning Solutions

Optimize your Consumer Goods Production with plus10!

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