---
title: "44% Less Downtime in High-Speed Filling"
description: "case-studies.case-fmcg-tpm.meta_description"
url: "https://niotek.net/en/case-study/fmcg-tpm"
language: "en"
---

FMCG • PACKAGING & FILLING# 44% Less Downtime. 16% Higher OEE.

How a global FMCG leader transformed its maintenance operations from reactive firefighting to a predictive TPM model, cutting downtime by nearly half and improving OEE—without replacing legacy control systems.

-44%

Unplanned Downtime

+16%

OEE Increase

46%

Faster MTTR

90%+

Schedule Accuracy

72%

Unplanned Downtime

-68%

OEE Increase

+12%

Faster MTTR

100%

Schedule Accuracy

### 01 // THE CHALLENGE

## When Every Minute Costs Money

In high-speed FMCG environments, efficiency margins are razor-thin. This facility operated multiple packaging and filling lines where every minute of downtime directly translated into lost revenue. Despite strong demand, operations were constrained by reactive maintenance.

#### Reactive Maintenance Culture

Equipment degradation went unnoticed until sudden failures occurred, forcing emergency repairs.

#### Fragmented Data

Work orders and history scattered across manual logs, limiting accountability.

#### The OEE Blind Spot

OEE calculated retrospectively masked real capacity losses.

### 02 // THE SOLUTION

## A Predictive TPM Command Center

case-studies/case-fmcg-tpm.sol\_desc

01

#### Unified Command

Centralized tracking of MTTR and MTBF. Maintenance teams now operate from a single shared source of truth.

02

#### Predictive Detection

Continuous monitoring of equipment health. Early warnings allow interventions to be planned instead of rushed.

03

#### Automated Workflows

Digitized preventive maintenance schedules. Work orders triggered and tracked systematically.

### 03 // THE RESULTS

## Before vs. After HORUS

case-studies/case-fmcg-tpm.res\_desc

case-studies/case-fmcg-tpm.res\_data\_source

Metric Before HORUS After HORUS Impact Unplanned Downtime ~52 hrs / month ~29 hrs / month 44% Reduction OEE Score 62% 78% +16% Gain MTTR 2.4 hrs 1.3 hrs 46% Faster Recovery Schedule Accuracy ~40% 90%+ 2.25× Improvement

### TECHNICAL SPOTLIGHT

#### Zero Rewiring Integration

Connected directly to existing PLCs on packaging and filling lines without modifying core control logic.

#### Root Cause Analysis (RCA)

Structured fault classification enabled faster diagnosis and repeat-failure elimination.

#### Cost Avoidance

Achieved 18–22% annual maintenance cost avoidance by extending asset life.

> "Predictive maintenance is not just about protecting machines. It’s about saving time."

Achieve significant OEE increase and reliability through software and process intelligence alone.

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OEE\_CALC.EXE

### Calculate Your OEE Potential

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Potential gain to reach 85% OEE (world-class standard)