Sidel launches Performance-Based Services to improve and sustain packaging-line efficiency

Sidel is launching Performance-Based Services, a new results-led approach designed to help manufacturers increase output, restore efficiency and reduce unplanned downtime across packaging lines.

Performance-Based Services combines Sidel’s complete-line expertise with performance analysis, root-cause investigation and workforce development. Rather than focusing on individual machines or one-off interventions, the approach identifies the factors limiting performance across the complete line and supports customers in implementing improvements against defined performance targets.

The launch builds on Sidel’s experience during five years across 120 line assessments and 80 performance-based service projects at customer sites worldwide. Reported project outcomes include a seven-point improvement in overall equipment effectiveness (OEE) on a UK PET line; a 70% reduction in unplanned downtime on an aseptic Combi in the US; and a 40% efficiency improvement on a returnable-glass bottle line.

“Our ambition is to be an extension of the plant’s operational excellence team; in other words, a performance partner,” says John Como, Director Performance-Based Services at Sidel. “Customers typically come to us with two challenges: protecting the performance of a newly commissioned line beyond the first year after Site Acceptance Testing (SAT), and improving the efficiency or output of an existing priority line, but have significant concerns over delivering the measurable improvement required.

Putting performance at the centre

Packaging-line performance is influenced by complex factors including equipment condition, maintenance routines and operator capabilities, operating standards, workforce skills and raw-material consistency or management. When any of these are less than optimum, recurring or chronic losses can be difficult to diagnose because the underlying issue may extend beyond an individual machine. Performance-Based Services looks beyond individual machine peculiarities or one-off interventions to understand what is holding back the line as a whole.

“A packaging line is a complex, connected system,” explains Como. “An immediate repair may resolve one issue today, but it will not necessarily address why performance was lost in the first place. We look holistically at the line, the people and processes to identify the main losses, understand their root causes and determine which actions will deliver sustained results.” 

From assessment to sustained improvement

The process begins with an assessment of line balance, critical equipment identification and production losses. Sidel combines on-site observations with performance-data analysis, simulations and, where appropriate, remote monitoring to identify bottlenecks and prioritise improvements.

The next phase combines Sidel's equipment and complete-line expertise with root-cause analysis and Total Productive Maintenance (TPM) methods. This can include restoring equipment condition, improving operating and maintenance standards, optimising line settings and building competencies within the local team. The next aim is to identify and commit to challenging performance targets linked to KPIs such as line efficiency or unplanned downtime.

“We do not want to stop at diagnosis and quick repairs,” says Como. “We work alongside our customers’ teams to put improvements into practice, monitor the results and adjust or respond as necessary, in order to deliver on the agreed performance commitment.”

Building performance from within

Through practical coaching, competency development and knowledge transfer, Sidel works with operators and maintenance teams to strengthen their autonomy and ability in maintaining equipment, identify emerging losses and continue improving performance after Sidel’s experts have completed their work.

“Sustainable performance means that the customer does not become dependent on us,” adds Como. “We transfer our knowledge to the people who operate the line every day. We often say that true performance is what stays after we leave.”

Proven results in the field

At a US plant producing premium protein drinks, teas and isotonic beverages, Sidel's project team worked alongside the local team over six months to restore critical machine sub-assemblies linked to recurring production losses, while introducing a structured competency-building and coaching programme. The project reduced unplanned downtime on the aseptic Combi by 70%.

For a UK producer operating a multi-SKU, multi-product PET line, Sidel carried out a complete line assessment that identified issues around line balance, conveying, controls and accumulation. A rigorously-driven corrective action plan contributed to a seven-point improvement in Overall Equipment Effectiveness (OEE) within a year.

Other projects include a 17-point improvement in OEE supported by remote performance monitoring;  a ten-point improvement across two beer-can lines; and a 60% reduction in changeover time on a PET carbonated soft-drinks line following updates to Standard Operating Procedures.

“Customers do not want an audit or training programme in isolation. They want more reliable production, greater output and efficiency, and stronger teams,” concludes Como. “Performance-Based Services brings together the expertise, in a structured way, needed to deliver measurable and sustainable improvements."