A Full AVEVA Experience for Olive Oil Manufacturing
About the Customer
In today's Food & Beverage landscape, Salov stands as one of the largest companies in the olive oil sector, boasting a consolidated turnover of over €491 million and 120 million liters sold in 2022. Founded in 1919, Salov Spa operates in the Italian market under the renowned Sagra brand and the Filippo Berio brand, which boasts over 150 years of history. Filippo Berio is distributed across more than 75 countries worldwide, with prominent positions in markets such as the United States, United Kingdom, Belgium, Switzerland and Hong Kong. With 5 subsidiaries, 3 resident managers, and 2 area managers totaling 314 employees, the Group's core values include a strong emphasis on product quality throughout the supply chain and a commitment to sustainability, which underpins numerous corporate initiatives.
Project Summary
The imperative to swiftly adapt to our ever-evolving reality prompted Salov to seek a solution through the digitization of its factory and the streamlining of its supply chain processes, commencing at a production site in Tuscany. Therefore, the olive oil manufacturer engaged Engineering Industries eXcellence to digitalize their factories and integrate their supply chain processes.
"The answer came with the OMNIA project, a pivotal moment in the digital transformation of Salov," explains Luca Greco, Salov's CIO, "with the implementation of new systems supporting production processes such as production planning, scheduling, and plant maintenance."
To accomplish this, our digital manufacturing team implemented a new production management solution founded on the integration of best-of-breed third-party and proprietary technology platforms. Consequently, the customer enabled real-time monitoring of their production, demand forecasting and inventory management processes from inception to completion.
Project Activities
- Provided strategic consulting and support services throughout Salov's digital transformation initiative
- Implemented a comprehensive Manufacturing Execution System (MES) based on AVEVA’s MES (formerly Wonderware) platform
- Enabled new production management capabilities via the integration of a customized scheduling tool with Salov's new MES solution
- Implemented a Digital Twin of Salov's finished goods factory and warehouse to optimize processes and decision-making
- Designed and deployed a customized Energy Management System (EMS) for sustainable manufacturing
- Designed and deployed a Customized Maintenance Management System (CMMS) to assist in managing assets, scheduling maintenance and tracking work orders
- Automated olive oil production quality management and reporting processes integrated with Enterprise Resource Planning (ERP)
Business Drivers
- Enable the end-to-end Digital Thread for Industry 4.0
- Attain real-time control of production processes
- Enable accurate production planning and reporting
- Manage production traceability and quality
- Optimize productivity and reduce waste
- Enhance collaboration across the enterprise
- Maximize resource and asset performance
More About the Project
In the fiercely competitive global context in which Salov operates, and due to heightened consumer demands for quality, innovation, sustainability and meticulous treatment of raw materials at all production stages, Salov was inspired to revolutionize their production systems through technological investment. The introduction of innovative digital solutions would also enable the olive oil manufacturer to adapt swiftly and flexibly to increased demand for their product and potential future food regulations.
Engineering Industries eXcellence was selected by Salov for OMNIA (Oil Manufacturing Next Information System Architecture), their internal program aimed at enhancing operational and organizational processes, systems and user experiences. Following an initial Industry 4.0 Assessment, which culminated in the creation of a digital transformation roadmap, our digital manufacturing experts designed and implemented a holistic Manufacturing Operations Management (MOM) solution, incorporating new MES and production scheduling solutions. AVEVA’s (formerly Wonderware) leading portfolio, including AVEVA MES Operations, AVEVA MES Quality, AVEVA Historian, AVEVA Batch Management and AVEVA MES Performance, as well as custom-built applications by our team, were identified as the appropriate software for the customer’s requirements. The utilization of these solutions facilitated faster data sharing and enhanced work organization, with an emphasis on placing the "human factor" at the forefront.
The OMNIA project also envisioned the establishment of an asset management platform for maintenance activities and an energy monitoring system for tracking energy consumption and environmental impact within the customer’s factory. This was accomplished through the implementation of concentrator Programmable Logic Controllers (PLCs) that make signals available across the customer’s 5 production lines and 55 perimeter machines connected to the MES.
In addition to digitizing and optimizing factory operations, the OMNIA project has delivered significant benefits to the customer’s supply chain. By integrating the company’s Enterprise Resource Planning (ERP) and data platform systems with production planning, maintenance management, and MES, our comprehensive solution has provided functional coverage across the Digital Thread for Industry 4.0. Coupled with an improved user experience, this has enabled the olive oil manufacturer, Salov, to significantly enhance the scope and intensity of their new systems' utilization, resulting in more efficient data sharing and increased efficiencies across the enterprise.
Engineering’s Advantage
Engineering Industries eXcellence is a key technology player that supported the customer throughout their entire digitalization project, from strategic consulting to actual implementation. The Engineering Group remains this leader’s Industry 4.0 partner of choice for enterprise transformation.
