Executive Summary
Keurig Dr Pepper invested in major capacity (e.g., Spartanburg, SC: ~1.5 million sqft Greenfield) and line modernizations to meet demand. Systemex delivered commissioning leadership and E&I support—loop checks, interlock validation, FAT/SAT coordination—and integrated maintenance programs into the CMMS, enabling safer startups and faster stabilization of brewing and packaging lines.
Highlights
- Commissioning management for automated packaging/brewing assets.
- Controls integration with PLC/HMI/SCADA and MES data handshakes.
- CMMS-ready PM programs from day one.
The Challenges
- Aggressive schedules for new lines and Greenfield ramp-ups.
- Integration risk with legacy automation and material handling.
- High cost of downtime in high-volume beverage operations.
Our Solution
Systemex applied its Operational Readiness, Commissioning, and Engineering & Technical Services expertise:
Commissioning & Technical Support
- Deployed commissioning managers and E&I technicians to execute loop checks, I/O validation, safety interlocks, and recipe verification.
- Ensured systems were fully tested and ready for operational turnover.
Vendor Coordination & Testing
- Coordinated vendor handovers and aligned FAT/SAT activities with as-built controls.
- Verified installation sequencing and functional performance across systems.
Reliability & CMMS Integration
- Built preventive maintenance libraries, structured BOMs, and loaded master data into the CMMS.
- Delivered operator and maintenance training to ensure smooth transition and ongoing reliability.
Defect Management & Commissioning Oversight
- Established defect/issue tracking processes and tiered daily commissioning meetings.
- Monitored progress, mitigated risks, and ensured timely resolution of system issues.
Results & Impact
- On-time startups with tighter first-week performance.
- Fewer commissioning defects and faster fault isolation.
- Improved reliability and quality yields post-start.
Services Applied
Operational Readiness & Commissioning; Engineering & Technical Services (E&I); CMMS & Master Data; Training & Capability Development; Planning & Scheduling.
Why It Matters
In the beverage industry, downtime translates directly into lost sales. Systemex’s commissioning and reliability integration helped Keurig minimize risk, accelerate production readiness, and ensure high product quality from the first day of operations.
Systemex Industrial Consulting – Industrial Risk Management
1111 Bd Dr.-Frederik-Philips, Suite 200, Saint-Laurent, QC
🌐 www.systemex.com | ✉️ infosic@systemex.com
