Laying the Foundation for Seamless Integration
BIC, a renowned manufacturing giant specializing in stationery, lighters, and shavers, embarked on a journey towards digital transformation with the objective of enhancing operational efficiency. Partnering with Plex and Rockwell Automation, BIC signed a multi-site Manufacturing Execution System (MES) subscription agreement to streamline their manufacturing operations across various facilities. The initial focus was on the manufacturing plant in Bizerte, Tunisia, catering to the Europe, Middle East, and Africa regions. The primary challenge faced by BIC was the need for standardization across all production processes while ensuring seamless horizontal and vertical integration of machines and workers.
Integration Through Simplification
BIC targeted replacing localized bespoke solutions with a unified cloud-based system accessible from any location. Selecting Plex MES for this transformation, BIC aimed to simplify and synchronize manufacturing tools, standards, and processes globally. By transitioning from multiple fragmented software solutions to a fully integrated execution system provided by Rockwell Automation's Plex MES, BIC overcame operational silos and enhanced collaboration among workers. This shift not only resolved inefficiencies caused by varying software and systems across factories but also provided a centralized platform for efficient data sharing and analysis.
Making Improvements on a Global Scale
The implementation of BIC's Plex MES solution encompassed 90 molding and assembly lines with diverse automation levels. Despite the complexity of the plant, BIC successfully deployed the MES Advance package, significantly enhancing shop-floor processes and productivity. The solution led to an impressive increase in daily production output, reaching over 100,000 finished product parts per shift. Key benefits included enhanced visibility into shop-floor performance, improved overall equipment effectiveness (OEE), and increased inventory accuracy. These improvements not only optimized production planning but also ensured full traceability from raw materials to finished goods and beyond.
Embracing a Standardized Approach
The success of the pilot project at BIC's Bizerte facility has set the stage for broader MES/MACH2 rollouts globally. With the seamless integration capabilities of Plex MES, BIC is poised to replicate the success achieved in Bizerte across its worldwide operations, fostering a standardized approach to manufacturing processes. The partnership with Rockwell Automation has been instrumental in driving BIC's vision of connecting operational technologies and IoT, facilitating a holistic integration strategy. As BIC continues its digital transformation journey, the emphasis remains on standardizing systems at a global level to bolster operational efficiency and drive continuous improvement.
Driving Operational Excellence
Going forward, BIC aims to leverage the flexibility of the Plex solution to tailor MES implementations to suit the specific needs of different facilities worldwide. With plans to expand the smart manufacturing initiative to locations like Athens, Manaus, and Mexico, BIC envisions a future where Rockwell Automation plays a pivotal role in their digital transformation journey. The collaborative efforts between BIC and Rockwell Automation underscore a commitment to generating significant enhancements across manufacturing operations, marking the beginning of a transformative phase in BIC's quest for operational excellence.