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CDC Factory helps $1.5M improvements flow at soft drinks manufacturer Calypso

ATLANTA, April 1, 2007—Calypso Soft Drinks introduced the CDC Software Real-Time Performance Management (RPM) solution as part of a 'War on Waste' program to improve the efficiency of its business processes, with the initial goal of a one percent reduction in raw material costs. IT director James Holmes now estimates that he will nearly double that saving.

"By the end of the financial year the efficiency improvements will be worth around $100,000 to $120,000 per line," he says. "That amounts to around $1.5 million a year."

Calypso's new OEE line measurement metric is now running consistently at 80 percent or more on all of its 13 production lines and the company has managed to improve productivity by between three and eight percent per line. The company has also managed to reduce stockholding by 50 percent without compromising OEE.

The company's shop floor operators have increased their speed on most standard downtime with quicker and more efficient product changeovers. The system extends way beyond the shopfloor, however; with a hundred screens throughout the business, anybody with log-in permissions - from the shopfloor operators to the chairman - can get a real-time picture of what's happening in the business.

Calypso Soft Drinks produces an extensive range of soft and freeze drinks in a variety of single-serve formats including cups, cartons, bottles and freeze pops. The company supplies over 500 million units a year to supermarket multiples, small retailers and gas station forecourts, as well as airlines, schools, and hospitals.