From "Manufacturing" to "Smart Manufacturing", Tech-Long Joins Hands with Kecheng to Empower the Digital Transition of FMCG Manufacturing

Tech-Long is a leading supplier of liquid packaging line equipment in China and Kecheng Information is the wholly-owned subsidiary of Tech-Long. Kecheng Information’s MOM system (Manufacturing Operation Management System) has been deeply integrated with the equipment, and is able to provide customers in the FMCG industry with a full chain of empowerment from equipment assurance to production optimization.

I. Guaranteeing production continuity to address the biggest pain point in the FMCG industry

FMCG production requires extremely high continuity of equipment operation as downtime brings huge losses. The MOM system achieves this through the following means:

1 Predictive maintenance of equipment

Real-time monitoring of vibration, temperature, pressure parameters of core equipment such as blow molding machines, filling machines, labelling machines, packaging machines, etc. with corresponding sensors, with early warnings of faults such as bearing wear and seal failure 48-72 hours in advance..

Result: Reduction of unplanned downtime by more than 30% and reduction of maintenance costs by 20%.

2 Remote expert support

When the equipment malfunctions, MOM automatically sends or manually uploads fault codes and operation logs. 80% of simple faults can be remotely resolved within 2 hours.

Result: Reduction in time to repair faults by 60%, reducing the customer's reliance on on-site engineers.

II. Enhancing production efficiency for responding to the needs for flexible production of FMCG products

FMCG production frequently changes products (e.g., beverage flavor changes, packaging specification changes), and the MOM system optimizes key steps:

1. Automated changeover management

The MOM system automatically sends recipe parameters (such as filling volume, temperature, pressure) to the equipment, while synchronously switching quality inspection standards (such as liquid level detection thresholds). Changeover time is reduced from an average of 45 minutes to 15 minutes.

Result: Improvement of economic efficiency for small batch orders to meet e-commerce and customization demands.

2 Real-time OEE (Overall Equipment Effectiveness) analysis

Automatically calculate equipment availability (A), performance rate (P), and quality rate (Q) to identify bottleneck links.

Result: For customers with small batch orders, OEE generally increases from 65% to above 80%, with equipment capacity improving by 20%.

III. Ensuring quality compliance to meet stringent standards in food and beverage

1. Full-process quality traceability

Each bottle of product is linked with production time, equipment parameters, operator, and raw material batch which is integrated with Kecheng code marketing system. In case of customer complaints, the defective batch can be identified and recalled within 2 minutes.

Result: Compliance with FDA/ISO22000 traceability requirements, reducing brand reputation risks.

2. Intelligent closed-loop quality inspection

When the vision inspection system identifies a defect, MOM notifies of maintenance and simultaneously adjusts upstream equipment parameters (such as correcting the position of the filling valve).

Result: Defective product rate dropped by 50%, saving millions in quality-related costs annually.

IV. Data-driven decision making for empowering customers with lean management

1. Optimization of utilities and materials consumption

Monitoring utilities consumption peaks, identifying high-energy-consuming processes (such as sterilizers); predicting the lifespan of wearing components (such as filling valve seals), and enabling demand-based purchasing.

Result: Energy consumption decreased by 15%, spare parts inventory reduced by 30%.

2. Automatic generation of production reports

Automatically output shift production, yield, and downtime cause analysis reports instead of manual Excel statistics, and support viewing on mobile devices.

Result: Production managers' decision-making efficiency improved by 50%, allowing them to focus on problem-solving instead of data collation.

Tech-Long’s differentiated value: Deep integration of equipment and MOM

Customer’s application case (typical scenario in the beverage industry)

Scenario:
A juice manufacturer in East China launches a new product and needs to switch between five flavors daily.

Empowerment results:
Changeover time reduced by 70% from 45 minutes to 13 minutes, with daily production increased by 12,000 bottles.

Through online detection of sugar content by MOM, mixing ratios are automatically adjusted, achieving 99.8% flavor consistency.

Quarterly equipment failure rate dropped by 40%, saving over 500,000 RMB in maintenance costs.