Executive Summary
Across multiple bottling and blending facilities, Bacardi’s maintenance practices had diverged, driving variability in changeovers, PM quality, and wrench time. Systemex delivered a global maintenance standard anchored in common PM libraries, SMEDdriven changeover reduction, and coaching for planners/supervisors. The result: faster changeovers, fewer emergency interventions, and crosssite KPI visibility.
Highlights
- Unified PM library & task lists covering common packaging and utilities assets.
- SMED workshops that cut changeover time and “firsthour” scrap.
- Planner & supervisor coaching with KPI dashboards and tiered meetings.
The Challenges
- Disparate standards by site and line; undocumented tribal knowledge.
- Reactive bias and firefighting on packaging assets.
- Inconsistent spares governance across storerooms.
Our Solution
Systemex applied its Operational Readiness, Commissioning, and Engineering & Technical Services expertise:
Global Preventive Maintenance
- Built a global PM catalogue covering filler, capper, labeller, case packer, conveyors, and CIP/utility systems.
- Standardized maintenance tasks to ensure consistent reliability across sites.
Process Optimization & SOPs
- Ran SMED and line balancing events to improve throughput and efficiency.
- Documented best-known methods into SOPs for repeatable, high-performance operations.
Planning & Scheduling
- Established planning and scheduling cadence with frozen weekly schedules, kitting, and disciplined close-out processes.
- Improved alignment between production, maintenance, and supply chain activities.
Performance Monitoring & KPIs
- Implemented KPI dashboards tracking wrench time, PM compliance, and planned vs. emergency work.
- Provided visibility into operational efficiency and maintenance effectiveness.
Leadership Coaching & Continuous Improvement
- Coached leadership on tiered accountability and RCA/Apollo methodology for chronic losses.
- Strengthened problem-solving capabilities and drove sustainable performance improvements.
Results & Impact
- Higher wrench time and PM compliance.
- Shorter changeovers and improved OEE on priority lines.
- Fewer emergency calls; more stable supply to markets.
Services Applied
Reliability Engineering, Training & Capability Development, Spare Parts & Inventory, Asset Criticality Assessment, Planning & Scheduling, Change Management & Governance.
Why It Matters
For multinational consumer goods companies like Bacardi, maintenance reliability ensures consistent production quality and supply chain stability. Systemex’s standardization and coaching program reduced risk, controlled costs, and created a repeatable framework for global operations.
Systemex Industrial Consulting – Industrial Risk Management
1111 Bd Dr.-Frederik-Philips, Suite 200, Saint-Laurent, QC
🌐 www.systemex.com | ✉️ infosic@systemex.com
