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11 Technologies Driving the Smart Factory Revolution

Here are 11 factory digitalization tools CPG brands are using to transform their facilities into smart plants.

Manufacturers are using AR and VR technology for training, maintenance, and quality control.
Manufacturers are using AR and VR technology for training, maintenance, and quality control.

The digital revolution in CPG manufacturing is happening now. In today's fast-paced business landscape, consumer packaged goods (CPG) brands are constantly striving to increase worker productivity and manufacturing flexibility to keep up with consumer demands, as well as to stay ahead of the competition.

One way brands are finding success is by automating manual processes and then layering a variety of software applications on top that can contextualize data to gain visibility into what’s happening on the plant floor. As more CPGs tap into these digital technologies, they are transforming traditional facilities into smart plants: efficient, data-driven centers of manufacturing excellence.

CPGs have varieties of digital factory software tools at their fingertips. These serve as a big-picture tool that integrates continuous optimization and fosters a connected worker culture of operational excellence. 

Let’s explore 11 tools that are making plants smarter and reshaping the industry for the better.

1. Data Analytics and Data Management Tools

Data is the backbone of any successful digital transformation, and the increasing availability of data is a catalyst to change. But first, CPG brands must be able to pull the correct data out of equipment. Sensors, instrumentation, controllers, and other devices are now generating more data than ever before. And data management tools can be used to sort through and contextualize the data, from which an analytics application can create actionable information—a key element of the next-generation smart plant. 

Data analytics and data management tools are essential for making sense of it all. They help businesses identify trends, patterns, and anomalies in their processes. Empowered with this data, brands can make informed decisions in factory digitalization about production planning, scheduling, equipment maintenance and more. For example, a smart food and beverage facility might use real-time data analytics to optimize their production line, reducing downtime and minimizing waste, ultimately leading to increased profitability.

2. Predictive Maintenance

Predictive maintenance has emerged as a game-changer in manufacturing. With machine learning algorithms, manufacturers anticipate equipment failures before they occur. Contingency planning becomes data-based and strategic, allowing for timely maintenance and preventing costly unplanned downtime. For a nutraceutical brand, this might mean improved equipment reliability, ensuring that critical processes are not interrupted, and production remains consistent and compliant with regulatory standards.

3. Track-and-Trace Technologies

In industries where safety and quality are paramount, such as pharmaceuticals and personal care, track-and-trace technologies are already transforming supply chain management. Through digitalization components like RFID tags and sensors, smart manufacturing facilities monitor their products' journey from production to the end consumer. Track-and-trace tools enhance product transparency, mitigates risks of counterfeiting, and facilitates recalls if necessary, boosting consumer trust and brand reputation.

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New e-book on Flexible Packaging
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