Tier-1 personal-care line: 960 additional bottles/hr, no new equipment
Production sits inside a contract manufacturing partner of one of the world's largest fast-moving consumer goods companies — a Top-5 global FMCG with €60B+ revenue and personal care brands sold in 190+ countries. Customer name disclosed under NDA on the call. Sector, geography, line OEMs and outcomes documented below
A global FMCG, its strategic European contract manufacturer, and the line that ships into 12 markets
Six things the team did
High-mix shampoo and conditioner filling, ~150 PPM, multi-shift, multilingual operator team
The line
Unilogo filler + FlexiCapper + FlexiLabeller, TransNova RUF palletizer downstream. Multi-shift, multilingual operator team
The challenge
Cap-sorter rejection rate climbing, vacuum-driven micro-stops on the delta robot, changeover variance ±18% between day and night shifts
What we deployed
Knowledge layer (auto-generated micro-lessons in 3 languages), CBM on capper torque and vacuum, Roberta pilot on weak-point monitoring
Result · throughput
960 additional bottles/hour recovered
Result · changeover
Variance compressed from ±18% to ±6%
Result · onboarding
New-operator onboarding from 14 weeks to 5
What changed in the first 6 months
Six-month rollout · contract to compounding gains
No big-bang. The line stayed in production while PackGuru installed, calibrated, and learned. Phased so each module had to earn its place before the next one went in
Knowledge layer
Captured every SOP, machine alarm code, and changeover recipe into a searchable graph. Auto-translated into PL/EN/UA. Operator queries answered in under 3 seconds at the HMI
Condition-based monitoring
OPC-UA telemetry from the FlexiCapper torque profile and vacuum pump pressure. PackGuru flagged seal degradation 4 days before the failure that would have stopped the line
Roberta pilot · weak-point monitoring
Roberta stationed herself at the cap-sorter — the line's documented weakest stage. Caught 11 micro-stops on day one. Live video stream to the maintenance lead's phone for tele-support
The knowledge that used to live in the heads of three senior operators is now searchable by anyone on shift, in their language
The same loss patterns appear on every multi-SKU personal care line
Cap-sorter rejection drift, vacuum-driven micro-stops, changeover variance between shifts. We see them every time. The fixes compound — and they don't require new capital equipment
See if your line has the same pattern
Send us your sector and your top loss line. We'll come back with the closest comparable case