Loading
Utility Header Logo
Plex Community
Change Country Site SelectionChange RockwellAutomation.com site selection to a different country, region or language
US | EN
Plex, a Rockwell Automation Company logo
Products
Manufacturing Execution System (MES)
Manufacturing Execution Suite (MES) is a comprehensive manufacturing software solution that provides real-time, paperless production management to drive enterprise-wide compliance, quality, and efficiency.
Quality Management System (QMS)
Quality Management System (QMS) is a cloud-based digital quality solution for manufacturers that standardizes and automates quality documentation, processes, and measurements.
Enterprise Resource Planning (ERP)
Enterprise Resource Planning (ERP) is a full-featured, scalable, cloudbased ERP that automates front- and back-office processes.
Supply Chain Planning (SCP)
Supply Chain Planning (SCP) combines data from your Plex ERP and multiple departments across your business to sync up demand and supply planning to improve inventory accuracy and production management.
Connected Worker
Connected Worker empowers frontline manufacturing teams with real-time digital tools to improve productivity, reduce errors, and enhance collaboration. It connects your people, to purpose, people, productivity, and processes to drive continuous improvement and workforce agility on the shop floor.
Production Monitoring
Production Monitoring provides seamless connectivity to machines on the plant floor, delivering transparent, real-time operational KPIs and dashboards to drive continuous improvements.
MES Automation & Orchestration
MES Automation & Orchestration connects your Plex MES to the plant edge to control information flow, processes, and workcenter setup adding efficiency, saving costs, and eliminating manual errors.
Asset Performance Management (APM)
Asset Performance Management (APM) combines process, operational, and machine-level data through highly visual dashboards to proactively monitor machine and plant health to ensure optimal uptime, throughput, and maintenance needs.
Finite Scheduler
Finite Scheduler is an advanced production scheduling tool that helps manufacturers optimize resources, reduce bottlenecks, and improve on-time delivery. It enables dynamic, constraint-based scheduling to align operations with real-world capacity and demand
Platform
Smart Manufacturing Platform Overview
Discover how our integrated platform connects, automates, tracks, and analyzes your operations.
Cloud Infrastructure & Security
Enterprise-grade cloud infrastructure with industry-leading security and compliance.
Mobile Application
Access critical manufacturing data and controls from anywhere with our mobile apps.
Availability & Performance
Industry-leading uptime and performance with 99.5% availability guarantee.
Manufacturing Automation
Seamless integration with Rockwell Automation and other manufacturing systems.
Industries
Aerospace Auto and Tire Food & Beverage Industrial Manufacturing Plastics & Rubber Precision Metalforming
Plex Generic Dark Background
INTERACTIVE DEMO
Plex MES for Automotive

Gain Real-Time Visibility and Control of Your Operations

Try Now
Resources
All Resources Success Stories Analyst Reports Knowledge Articles Demos Blog
Plex Generic Dark Background
Analyst Report
2025 Gartner® Market Guide for Manufacturing Execution Systems
Read More
TALK TO US
SEE A DEMO
Log In Plex Manufacturing Cloud Plex Classic
TALK TO US
SEE A DEMO
Case Study
Recent ActivityRecent Activity

Summer Garden Food Manufacturing Reduces Downtime and Improves Machine Performance

Download Case Study

Share This:

LinkedInLinkedIn
XX
FacebookFacebook
PrintPrint
EmailEmail
Summer Garden Food Manufacturing

With an operation that runs two 12-hour shifts a day, 5 days a week and produces up to 100,000 cases of sauces weekly, overall equipment effectiveness (OEE) is a priority. But until Summer Garden Foods installed Plex Production Monitoring in late 2022, they lacked the data visibility needed to ensure equipment was performing as efficiently as possible.

At A Glance

  • Reduced downtime
  • Improved machine performance
  • Operator insight into personal daily OEE

We have so many options when it comes to Plex. And it’s so simple whether it’s an add-on module or extra programming. You couldn’t ask for anything easier than that.

Jason Morrow - Controls Technician, Summer Garden Food Manufacturing
 

“We were missing downtime. We knew we had it, but we couldn’t find it. Our kettle yields weren’t equaling our run times. We wanted to start tracking downtime at a more detailed level than the piece of paper the operator writes,” Jason Morrow, controls technician with Summer Garden Food Manufacturing, explains. “Plex is easily scalable. We could start with one machine and then build off that once we knew what we’re doing. The scalability was one of the biggest reasons we went with Plex.”

Downtime Minutes Add Up 

The first task for Summer Garden Food Manufacturing was tracking downtime on a key piece of equipment: the filler machine. The machine’s processes are controlled by Rockwell Automation 5300 series ControlLogix programmable controllers, which meant they were already collecting a lot of data. Using Plex Production Monitoring, the food manufacturer was able to easily program and extract data reports that pulled data from the Rockwell Automation controllers and several other sources.

“We found we had four hours of downtime per shift. Operators were repeatedly opening the door which stops the machine, making adjustments, and then closing the door. A minute here, two minutes there, five minutes here add up substantially throughout a shift,” Jason says. “But the operators weren’t writing it down. They didn’t think it was anything big. Yet, three to four hours of downtime a shift is a ton of downtime.” 

With that valuable insight, the company is now focused on improving operator training and control to help improve machine performance. One tactic Summer Garden Food Manufacturing is undertaking is development of a visualization screen that provides operators insight into their personal daily OEE to facilitate individual awareness and growth.

Increasing Production with Further Machine Visibility 

Next on its digital transformation journey, Summer Garden Food Manufacturing plans to expand the number of machines on its Plex platform. 

“We started small. Now we’re going to branch out to the machines further down the line that may be causing the filler idle time. I’m sure there’s micro downtime we’re missing on the rest of the machines,” Jason explains. “There should be a ton of information. It’s just digging into all that and eventually it should increase production.” 

From there, Summer Garden Food Manufacturing will analyze manufacturing data by product, such as comparing the run times of different sauces.

“How do we improve the operation of the red sauce or the barbecue sauce so we can get the same speeds out of each product?” Jason offers as an example. “We have so many options when it comes to Plex. And it’s so simple whether it’s an add-on module or extra programming. You couldn’t ask for anything easier than that.”

About Summer Garden Food Manufacturing

Summer Garden Food Manufacturing

Summer Garden Food Manufacturing manufactures and packages products for the retail and food service markets including various barbecue and pasta sauces. Known for their creative product innovations, unparalleled quality and their commitment to excellent customer service, Summer Garden Food Manufacturing continues to produce their flagship brand, Gia Russa, celebrity chef brands, private label and store brands.

Industry: Food and Beverage

Location: Ohio

Published July 19, 2023

Topics: Food & Beverage Smart Manufacturing Digital Transformation Success Stories

Featured Resources

Loading
Loading
Loading
  1. Chevron LeftChevron Left Homepage Chevron RightChevron Right
  2. Chevron LeftChevron Left Case Studies Chevron RightChevron Right
  3. Chevron LeftChevron Left Summer Garden Food Manufacturing Reduces Downtime And Improves Machine Performance Chevron RightChevron Right
Products
Manufacturing Execution System (MES) Quality Management System (QMS) Enterprise Resource Planning (ERP) Supply Chain Planning (SCP) Connected Worker Production Monitoring MES Automation & Orchestration Asset Performance Management (APM) Finite Scheduler
Platform
Smart Manufacturing Platform Cloud Infrastructure & Security Mobile Application Availability & Performance Manufacturing Automation
Resources
All Resources Case Studies Analyst Reports Knowledge Articles Demos Blog
Industries
All Industries Aerospace Auto and Tire Food & Beverage/CPG Industrial Manufacturing Plastics & Rubber Precision Metalforming & Fabrication
Services & Support
Customer Success & Advocacy Support Services Educational Services Professional Services Plex Community
Get Started
Request a Demo Download Resources Read Success Stories Webinars Contact Support
Company
About Us Why Plex Recognition Newsroom Careers Contact Us
Knowledge Articles
Types of Quality Management Systems The MES Beginner Guide A Guide to Production Part Approval Process What is Industry 4.0? A Guide to Advanced Product Quality Planning Supply Chain Planning: A Guide to Strategic Planning and Operations MES and the Future of Robotics Automation Cloud Based MES Basics Food Manufacturing Software: Why MES Is Critical for Food and Beverage Manufacturers Guide to Failure Mode and Effects Analysis (FMEA) Cloud-Based MES Solutions A Guide to Monitoring Machine Performance What is Connected Manufacturing and Why Should You Care About It?
Privacy & Cookie Policy
Terms & Conditions
Cookie Preferences
Accessibility Settings
Trust Center
© YYYY Plex, by Rockwell Automation. All rights reserved.
© YYYY Rockwell Automation, Inc.