Digital Manufacturing Solutions for Aluminum Beverage Can Production

This case study details the collaboration between a leading global aluminum beverage can manufacturer and ITC Infotech to implement digital manufacturing solutions aimed at improving operational and cost efficiencies. The manufacturer operates 18 plants across Europe with 42 interconnected product lines, impacting over 125 key performance indicators. The primary objectives included reducing aluminum spoilage loss, enhancing shop floor productivity, and improving regulatory compliance. ITC Infotech conducted an analysis of the manufacturing processes to identify challenges and align operational performance with business objectives. Solutions implemented included the creation of an enterprise control tower for real-time insights, digitization of over 95 quality logbooks integrated with SAP, and a digital twin solution for the production line. The results of these initiatives included a $16 million annual savings from reduced spoilage loss, a 9% reduction in spoilage, a 12% improvement in operator productivity, and a 22% increase in asset utilization, leading to an additional $4 million in annual savings.