Case Study - Fortune 500 Food Producer

Food producers operate in a high-volume, low-margin environment. Even minor inefficiencies, like a few grams of excess material per unit or inconsistent process settings, can scale into major costs across millions of units produced.

A leading food producer sought to reduce process variation. Its centerlining was suboptimal due to a lack of reliable tools that allowed for real-time line improvements.

Ethon identified the root causes of material overusage and recommended setpoint changes that improved centerlining performance by more than 10×. In extensive benchmarking, it outperformed all previously used software solutions, which could not identify the causes of the prevalent process variation. The implementation was hands-on, with strong support for process engineers and IT teams, which led to strong user adoption and fast data pipeline setup.

E2E data integration: Built end-to-end pipeline to give live recommendations for improved line stability.

Drive cost-reduction: Optimized centerlining drove ~$100,000 cost-savings per line and year.

Identified key parameters: Identified critical drivers of process variation and provided operators with setpoint recommendations.