CASE STUDY: Preventing Catastrophic Downtime in 24/7 FMCG Production with Custom Solutions

Background

A leading FMCG (Fast Moving Consumer Goods) company in the toilet roll production sector faced a critical challenge that threatened their 24/7 production line. This line relied on an adhesive application cell, a pivotal element in the production process. However, due to unforeseen breakdowns and the unavailability of a spare actuator, the company was operating at risk. To make the issue worse, the existing actuator model was obsolete, making it impossible to order a direct replacement.

The customer had been forced to salvage components from failed units, combining parts from old and new models. This workaround was unsustainable and increased the likelihood of catastrophic downtime. They urgently needed a reliable spare actuator and other mechanical components to ensure continuous production and mitigate the risk of unplanned stoppages.

Challenges

The factory faced a plethora of challenges, mainly obsolete equipment, as the original actuator model was no longer manufactured. This left them with a high risk of downtime, as without a suitable spare unit, any new breakdown could halt production entirely.

Due to the obsolete parts, the factory was left with complex compatibility issues, as mixing components from different generations of equipment increased the complexity and risk of further failures. This meant a quick solution was needed to prevent a potential production crisis.

Solution

The customer turned to Garry Haines, Linear & Automation Product Manager, known for his expertise in sourcing and supplying industrial components. To find the best solution possible for the customer, Garry conducted a specification and compatibility analysis to identify the specifications of the obsolete actuator and highlight the differences between the old and new models to ensure compatibility with existing systems.

Beyond the actuator, Acorn’s experts reviewed other elements of the drive chain and identified additional requirements. These included a replacement gearbox and an upgraded coupling to enhance performance and reliability.

ACORN quickly sourced and supplied all necessary components. By collaborating with product specialists, they ensured that each part met or exceeded the latest application requirements.

Results

Thanks to ACORN’s swift intervention, the customer now has a complete spare unit, including the actuator, gearbox, and upgraded coupling. They can plan a scheduled maintenance shutdown to replace the old unit, eliminating the risk of unplanned downtime. The new components’ enhanced specifications provide greater reliability and ensure the production line meets current and future demands.

Conclusion

This case highlights ACORN’s ability to deliver tailored solutions under pressure. By combining technical expertise and a robust supply chain, they resolved a critical issue for the customer, ensuring uninterrupted production in a high-stakes FMCG environment. This proactive approach not only averted a potential production crisis but also provided the customer with long-term operational resilience.

For industries where downtime is not an option, ACORN continues to be a trusted partner in delivering innovative and reliable solutions.