Complete CMMS solution for FMCG manufacturing operations

During an unannounced FDA inspection at a ready-to-eat salad facility in California last October, the investigator asked the quality manager to produce hygiene inspection records for three specific production...

A frozen meals manufacturer in Tennessee discovered the true cost of traceability gaps when a customer complaint about an allergen triggered a recall investigation. The quality team needed to identify every...

A frozen meals manufacturer in Tennessee discovered the true cost of traceability gaps when a customer complaint about an allergen triggered a recall investigation. The quality team needed to identify every...

A cereal manufacturer in Ohio spent 14 months evaluating AI platforms. They attended conferences, received demos from six vendors, commissioned a feasibility study, and formed a cross-functional steering...

A beverage bottling plant in Georgia was spending $2.8 million annually on water and $1.9 million on energy — and had no reliable way to determine where either resource was being wasted. Monthly utility bills...

A snack manufacturer in Indiana was shipping 0.4% defective product to retailers — undersized chips, broken crackers, packages with seal failures, and units with foreign material contamination flags from metal...

A frozen pizza manufacturer in Pennsylvania was losing 4.7% of every mozzarella batch to yield variation — not because the recipe was wrong, but because the recipe was static. The formulation assumed constant...

A frozen vegetable processor in the Pacific Northwest issued a Class I recall in late 2024 after routine post-distribution testing detected listeria monocytogenes across 14 product SKUs shipped to 2,300 retail...

A mid-size snack food manufacturer running six high-speed packaging lines across two shifts performed 22 changeovers per day — product changes, format switches, and flavor transitions that consumed an average...

A cereal manufacturer in the Midwest ran Six Sigma on paper — control charts printed weekly, Cpk calculated in spreadsheets, corrective actions tracked on whiteboards. The program delivered results in its...

A beverage manufacturer in Ohio was running 1.8 million bottles per week through two filling lines with manual cap inspection — operators stationed after the capper watching closures pass under angled...

A frozen meals plant in Pennsylvania was running maintenance the way most food factories still do: technicians responding to breakdowns, supervisors managing work orders on whiteboards, and spare parts tracked...

A snack manufacturer in Texas was running 14 production lines across three shifts with inventory managed through a combination of ERP min-max settings configured in 2019 and a warehouse supervisor who knew where...

A dairy processor in Wisconsin received an FDA warning letter after an investigator pulled 36 containers of Greek yogurt from a retail shelf and found that 11 carried date codes printed three days past the lot's...

A cereal manufacturer in Ohio was losing $2.3 million annually in raw material waste — and nobody knew the real number until they installed sensors on their mixing, extrusion, and packaging lines. The losses...

It's 2:00 AM in a 750,000 square-foot FMCG distribution center. The quarterly inventory audit begins—14 workers on scissor lifts and forklifts, spending the next 72 hours counting 180,000...

A snack foods manufacturer in Ohio spent 14 months building the business case for a robotic palletizing cell on their highest-volume line — and the CFO rejected it twice. Not because the numbers were wrong,...

A beverage company in Georgia was rejecting 1 in every 340 cans for label misregistration — a defect rate their standard vision system called acceptable because the printed text remained legible. What the...

A cereal manufacturer in Michigan spent $2.4 million installing two new palletizing robots and a vision-guided case packer on Line 7 — and the project ran 11 weeks behind schedule. The robots arrived, were...

A frozen pizza manufacturer in Ohio discovered the breach on a Thursday afternoon — not through their SIEM dashboard, but because two palletizing robots on Line 3 started placing cases at a 15-degree offset,...

A confectionery manufacturer in Pennsylvania was losing 2,300 units per shift to gripper-related damage — vacuum cups on the pick-and-place robots were leaving surface marks on chocolate-enrobed bars during...

A snack manufacturer in Texas was running cloud-based defect classification on its robotic pick-and-place line — high-resolution images captured at the robot's end-effector, sent to a GPU cluster in a regional...

A dairy processor in Wisconsin installed four collaborative palletizing robots on its refrigerated packaging lines in 2023, expecting the same throughput gains it had achieved on ambient-temperature lines....

A national FMCG brand shipping 340,000 e-commerce orders per week from three fulfillment centers discovered that 4.2% of outbound shipments contained at least one picking error — wrong SKU, wrong variant,...

A warehouse manager discovers 14,000 units of a seasonal SKU sitting in the wrong aisle three days before a Walmart promotional deadline. A grocery distribution center ships 6% fewer cases than invoiced because...

In March 2024, a frozen meal manufacturer recalled 8.7 million pounds of product after a vision system at a co-packer flagged a label mismatch — undeclared milk protein on a "dairy-free" SKU — but the...

A cereal manufacturer in Ohio deployed six collaborative palletizing robots on its packaging lines in 2023, expecting a straightforward productivity gain. Within four months, two operators had filed injury...

A snack manufacturer running 47 active SKUs across three packaging lines loses 22% of available production time to changeovers — format changes, tooling swaps, label reloads, and recipe parameter adjustments...

A listeria outbreak traced to a single conveyor belt return roller cost a mid-size FMCG processor $47 million in 2024 — product recalls, lawsuits, and a 14-month FDA consent decree that froze two production...

North American FMCG manufacturers face a convergence of pressures in 2026: ESG mandates from retailers like Walmart and Costco, rising energy costs that have climbed 23% since 2022, and consumer demand for...

Every year, North American FMCG producers discard an estimated $18 billion worth of product damaged during handling — bruised avocados, crushed pastries, cracked cosmetic compacts, and dented beverage cans...

A single misaligned cap on a bottling line doesn't just create one defective unit—it creates a chain reaction. The retailer flags it. The consumer photographs it. The social media post goes viral before your...

In 2026, the average North American FMCG plant is spending 18% more on labor than it did three years ago. Energy bills across the U.S. and Canada have surged past pre-pandemic benchmarks. Raw material volatility...

A multinational snack manufacturer's flagship packaging line ran 14 six-axis robots across three cells — pick-and-place, case packing, and palletizing. In March 2025, Robot 7's J4 axis servo motor failed at...

Between January 2024 and February 2026, peer-reviewed robotics research output targeting FMCG production applications increased 62% over the prior two-year period — driven by three converging breakthroughs:...

A frozen foods distribution center outside Memphis was running 14 sit-down forklifts across three shifts to move pallets between production end-of-line, cold storage staging, and outbound dock doors. Driver...

A beverage bottling plant in North Carolina was running 14 vision cameras across four filling lines — inspecting fill levels, label placement, cap torque indicators, and date code legibility at a combined...

A snack foods manufacturer outside Indianapolis was running three packing lines with six operators per shift dedicated to case packing, lid placement, and visual defect inspection. Turnover on those positions...

A mid-size FMCG bottling operation in Georgia was running three manual palletizing stations at end-of-line, each staffed by two operators per shift. Throughput capped at 14 cases per minute per station....

A regional FMCG distributor in the Dallas–Fort Worth metro ran a 90-day pilot delivering convenience-store replenishment orders by quadcopter across a 12-mile suburban radius. Average delivery time dropped...

A top-five North American FMCG distributor running 1.2 million square feet of warehouse space deployed 86 autonomous mobile robots across two distribution centers and integrated them with a CMMS-driven...

A multi-site FMCG manufacturer running 14 packaging lines across three facilities discovered that their legacy PLC architecture could not support the flexible product changeovers their retail customers...

A mid-size FMCG packaging facility was running six robotic case-packing lines 22 hours a day—and still missing weekly production targets by 11%. Unplanned stops averaged 47 minutes per shift. Operators logged...

Every minute a shrink wrap line goes down, cases stack up on conveyors, pallets miss their dock appointments, and retail customers start fielding out-of-stock alerts. For fast-moving consumer goods manufacturers...

Every FMCG facility running robotic case packing knows the math: a single end-of-line cell handles upward of 30...

When an autonomous mobile robot (AMR) stops mid-aisle during a peak-season night shift, the immediate cost is the pallet it was carrying and the 12 minutes a technician spends rebooting it. But when the same AMR...

Every minute your high-speed filling line is down, you are not just losing product — you are losing $5,000 to $15,000 in unrealized revenue, burning through expedited shipping budgets to meet retailer delivery...

At 2:47 AM on a Thursday in March, a high-speed labeling line at one of North America's largest household products manufacturers applied 14,000 units of incorrect regulatory text—a Spanish-language hazard...

In Q3 of 2024, a leading North American snack manufacturer discovered that a vision-guided pick-and-place robot on their primary packaging line had drifted 0.4mm outside its calibration...

When a pick-and-place robot jams mid-cycle on a high-speed FMCG sorting line, the cascade is immediate: product backs up on the infeed conveyor within seconds, upstream processes halt within minutes, and your...

A single unplanned stop on a high-speed FMCG packaging line costs between $5,000 and $15,000 per hour in lost output, wasted materials, and recovery labor. Multiply that across 14 robotic cells running three...

A dairy manufacturer in the Midwest shipped 14,000 cases of flavoured yogurt cups to retailers across six states. Three weeks later, a consumer reported finding a plastic fragment inside a sealed cup. The root...

Every FMCG plant runs on secrets — proprietary recipes, process parameters, formulation ratios, supplier blends, and quality control algorithms that took decades and millions in R&D to develop. When you...

The plant manager was sitting in a quarterly review when her phone buzzed. Line 3's filler had dropped to 78% speed—a pattern the AI recognized as a developing valve seal issue. She tapped the alert, saw the...

The production manager stared at the dashboard showing Line 4's output for the third consecutive week: 312 units per minute against a rated capacity of 420. The line wasn't broken—it was running. Every machine...

It's 4:47 AM on a Thursday. A 53-foot trailer backs into dock door 7 at a regional FMCG distribution center. The pick team loaded 26 pallets overnight—mixed SKUs of cereal, snack bars, and beverages bound for...

The sustainability director stared at three different spreadsheets, each maintained by a different department, each telling a different story about the plant's water consumption. Manufacturing reported 4.2...

A major cereal manufacturer shipped 22,000 cases of a nut-free children's product with labels from a different SKU—one containing almonds. The packaging line had run a changeover 90 minutes earlier, and four...

The FDA inspector arrived at 9:15 AM on a Tuesday. By 9:47 AM, the plant manager knew they had a problem. The inspector asked for CCP monitoring records from the previous Thursday's second shift—specifically,...

Your beverage line runs 1,200 bottles per minute. At that speed, a fill-head drifting just 2% high doesn't look like a crisis—but it is. Over a single 16-hour shift, that 2% overfill on one head gives away...

Line 4 at a mid-size beverage bottling plant runs 22 hours a day, 6 days a week. The nameplate capacity is 600 bottles per minute. But last quarter, the line averaged 389 bottles per minute—a 64.8% OEE that...

The plant manager was sitting in a quarterly review when her phone buzzed. Line 3’s filler had dropped to 78% speed—a pattern the AI recognized as a developing valve seal issue. She tapped the alert, saw the...

A beverage bottling plant in Ohio lost $340,000 in a single weekend. A bearing in their rotary filler seized at 2 AM Saturday—destroying the spindle assembly, contaminating 14,000 bottles of product already in...

A plastic fragment 2mm long sits inside minced meat batch heading to packaging. Metal detectors miss it (non-metallic). X-rays miss it (similar density). Human inspectors miss it (embedded, invisible)....

Your packaging line runs 600 units/minute. Manual inspectors catch 85% of label defects, miss fill-level variations under 3mm, and cannot verify 100% of seal integrity. AI vision systems inspect every package at...

Your production line generates 2TB of data daily—equipment sensors, quality cameras, process parameters, energy consumption. Without AI, this data sits unused. With AI solutions, patterns emerge: vibration...

A vibration sensor detects bearing degradation on your primary mixer 14 days before failure. Scheduled replacement during weekend downtime costs $1,200. Without predictive warning: catastrophic failure during...

A 600-unit/min packaging line stops unexpectedly. Hour one: $8,000 lost production. Hour two: $16,000 total. Emergency technician arrives hour three, diagnoses bearing failure, orders expedited part—24-hour...

A packaging line running at 600 units/minute suddenly slows to 480 units/minute. Without IoT monitoring, operators notice the slowdown 15 minutes later during routine checks—2,400 lost units. With IoT sensors...

Your packaging line processes 450 units per minute when running perfectly. Three weeks later, throughput has degraded to 398 units per minute. That's 52 units lost every 60 seconds. Over an 8-hour shift, your...

Your GFSI auditor found the gap: "Documentation incomplete." Not because your quality controls failed—because you couldn't prove they worked. Missing calibration dates. Lost sanitation logs. Temperature...

A mixer bearing scheduled for preventive replacement costs $2,800 during planned downtime. Ignoring it until failure during production: $21,700 in emergency repairs, lost output, and penalties. That $18,900...

Your facility just discovered $180,000 in annual waste hiding in plain sight. Not from renegotiating supplier contracts or cutting headcount—from something simpler: Oxmaint's CMMS identified compressed air...

Your facility just reduced annual energy consumption by 18% without installing a single solar panel. The savings came from something simpler: Oxmaint's CMMS platform identified equipment running inefficiently,...

Your analytics dashboard shows 94% inventory accuracy, 2.3-day average fulfillment speed, and 87% on-time delivery. The data looks excellent. Then your packaging line's bearing fails unexpectedly, halting...

Your production line just completed 847,000 units today—without a single quality defect reaching packaging. Not because you hired more inspectors, but because automated vision systems caught every misaligned...

Your warehouse holds $2.4 million in FMCG inventory right now. But here's the uncomfortable truth: $912,000 of that—38% of your total stock—is excess inventory that shouldn't be there. Those cases of...

Your production line just prevented a $50,000 recall. Not because a quality inspector caught a defect—because Oxmaint's AI-powered vision integration detected a 0.3mm packaging seal irregularity at 300 units...

Last quarter's forecast predicted 12,000 units. You produced 12,000 units. Actual demand: 16,500 units. The 4,500-unit stockout cost $81,000 in lost sales and emergency expedited production added $24,000. This...

A demand forecast predicted 2,500 units. Actual demand: 4,100 units. The stockout cost $18,000 in lost sales and $7,200 in emergency production. Meanwhile, another SKU sits with 40% excess inventory from...

The FMCG production line that ran efficiently in 2020 won't survive 2025. Traditional manufacturing approaches—paper-based logs, reactive maintenance, disconnected systems—now represent competitive...

Your high-speed packaging line runs at 600 units per minute when it runs. But it only runs 67% of scheduled time. When it does run, it operates at 82% of design speed due to micro-stops you can't quite identify....

The FDA inspector arrives unannounced at 9:47 AM. Your quality manager spends the next 90 minutes locating temperature logs from three different filing cabinets, assembling sanitation records from six...

The packaging line runs at 600 units per minute. An operator adjusts the wrong parameter during a changeover. Within 47 seconds, 470 defective packages exit the line before anyone notices. The cost? $8,200 in...

Your quality manager just spent three hours manually compiling data for an FDA audit. The finished product lot that shipped yesterday? It contained a batch with incomplete temperature logs because someone forgot...

The FDA inspector asks for your traceability records. You have 24 hours to provide them in electronic spreadsheet format. Can you do it? If your answer isn't an immediate "yes," you're not alone—and you're...

Your production line just lost 47 minutes to an unplanned changeover. Again. The OEE report shows 68% efficiency, but you're not sure if that's competitive or concerning. Meanwhile, your scrap rate hovers around...

The recall notice went out at 3:47 PM on a Tuesday. By Wednesday morning, your product was national news. By Friday, the FDA penalty letter arrived. By month's end, your largest retail partner had pulled your...

Your maintenance team performed 42 scheduled preventive maintenance tasks last month. Cost: $127,000. Hours invested: 336. Equipment still experienced 3 unexpected failures during production runs, costing an...

A 47-minute production stoppage can drain $28,200 in lost output—that’s $600 every minute. In FMCG manufacturing, where net margins often hover around 6%, a single unplanned breakdown can wipe out the profit...