Henkel
Henkel harnesses its big data to drive substainability and boost energy efficiency
Thanks to its successful implementation of the AVEVA Manufacturing Execution System, Henkel has significantly reduced filling line waste and virtually eliminated incorrect labeling (achieving 100% label quality ex-line and over 99.8% first-time right for label application globally). This has led to the highest guaranteed product quality and substantial packaging savings. Additionally, the solution improved Overall Equipment Effectiveness (OEE) by an average of 15% within just two years.
Download
Goals
- Reduce specific energy consumption and confirm ISO 50001 certification for all Laundry and Home Care production sites.
- Improve supply-chain resource efficiency on the production side by 5-6% annually.
- Become three times more efficient by 2030.
- Improvements were needed in the collection, use and communication of consumption and emissions data across the length of Henkel’s global supply chain.
Solutions
- AVEVA System Platform
- AVEVA Historian
- AVEVA MES Performance
Results
- Solution support for growth and sustainability strategies has resulted in incremental reduced year-on-year energy consumption, by up to 16% in 2020, on top of other on-going reduction measures,such as investing in more sustainable process and automation equipment.
- Annual energy cost savings are growing, reaching an incremental €8 million, driven by digital analytics in 2020.
- Energy cost savings to date have topped €37 million.
- Exponential ROI delivered: full payback delivered within four years; quadrupled ROI after eight years.
- Reduction in filling line waste and elimination of all incorrect labelling resulting in 100% label quality.
- Improvements of 15% in overall equipment effectiveness (OEE) after just two years.
He is talking about the project
“We adopted a digital backbone as this facilitates a vertical approach, meaning we can implement any add-on application in a ‘plug-and-play manner’ across the entire global value chain within months. In our experience, this is not only faster (than creating then duplicating a state-of-the art site), but also ensures each application roll-out quickly generates tangible business benefits.”
Dr. Dirk Holbach
Corporate Senior Vice President, Henkel
“When we introduced our AVEVA solution in 2013 we were already achieving a 3% year on-year energy saving on every ton of product produced. Once we’d implemented the solution, we saw a clear increase in energy efficiency. The AVEVA-based EMS solution has reduced Henkel’s energy consumption (kWh/t) year-on-year, by up to 16% in 2020, on top of our regular activities. To put this into perspective, the energy saved is equivalent to the capacity needed to support the three million inhabitants of two European capital cities, Amsterdam and Vienna.”
Wolfgang Weber
Corporate Director, Henkel
“In this project, we successfully made our worldwide energy consumption data available to supply chain managers in real time. This was an enormous step forward. Having implemented clear optimization measures in the last few years, we are now focusing increasingly on benchmarking and leveraging machine learning for more complex and energy-intensive processes, like spray-drying of laundry powder detergents. This will enable us to continue to significantly contribute towards achieving our sustainability goals.”
Dr. Dirk Holbach
Corporate Senior Vice President, Henkel
“In term of our vision for the future, the AVEVA software solution will continue to be an efficient tool that Henkel uses to achieve its goals. We are now working with AVEVA in other business units to drive further sustainability success. Sustainability and efficient use of resources is firmly anchored in Henkel’s corporate values – and this isn’t something recent. We were one of the first companies to start publishing an annual sustainability report thirty years ago. We have our sights set firmly on our long-term sustainability goals, and are proud that our commitment is frequently recognized by external bodies, such as the World Economic Forum (WEF) and the Dow Jones Sustainability Index (DJSI).”
Dr. Dirk Holbach
Corporate Senior Vice President, Henkel
“Henkel has always had a flair for implementing creative ideas to save energy effectively. The real challenge here was to gain a good pool of data.”
Dr. Johannes Holtbrügge
Senior Manager, Henkel
prev
next
Discover how to improve your OEE
Analyze the data collected from the operation to plan and validate improvement strategies. A data-driven approach guides business decisions for solid and sustainable growth.
Learn more
Are you interested in this project?
If you would like to learn more about the software we implemented for this client, contact us and we will get back to you.