Amazon IXD – VGT2 Las Vegas: Coca-Cola Bottler Transforms Manufacturing with AWS

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Coca-Cola İçecek (CCI) ranks as the sixth largest bottler of Coca-Cola products globally. Based in Istanbul, Turkey, CCI boasts impressive figures, manufacturing 1.2 billion cases of beverages each year across 26 bottling plants located in 10 countries, including Turkey, Azerbaijan, Iraq, Jordan, Kazakhstan, Kyrgyzstan, Pakistan, Syria, Tajikistan, and Turkmenistan, serving around 400 million consumers.

To enhance its manufacturing facilities, CCI is developing a digital replica—a digital twin—hosted in the cloud. This initiative aims to harness advanced analytics, artificial intelligence (AI), and real-time asset monitoring. CCI has even created a replicable framework that other Coca-Cola bottlers can use to implement similar digital manufacturing solutions in their operations.

Understanding the Digital Twin

The demand for connected, digital, and automated supply chains and manufacturing processes is booming, especially in the Consumer Packaged Goods (CPG) sector. Over 80% of our global Food & Beverage clients are seeking supply chain and manufacturing solutions from AWS.

Here are some essential manufacturing terms to know:

  • Digital twin: A virtual representation of physical manufacturing assets that utilizes sensors to gather data from machinery. This cloud-based twin showcases the real-time status of its physical counterpart, aiding technicians in diagnosing issues like damaged components or performance limitations.
  • Connected factory: A manufacturing site equipped with technology that facilitates seamless information sharing among personnel, machines, and sensors, whether within a single facility or across multiple locations. Insights from connected factories empower employees to enhance operations, quality, performance, and profitability.
  • AI and machine learning (ML) in manufacturing: Algorithms that mimic human cognition to assess data and make informed decisions. Applications include optimized production scheduling and predictive analytics that identify potential machine failures before they arise.
  • Industrial IoT: In this context, machines are outfitted with internet-connected sensors. These sensors relay data to an Industrial Internet of Things (IIoT) analytics platform, leveraging AI and ML to derive actionable insights.
  • Industry 4.0: Known as the fourth industrial revolution, this term describes the integration of smart technologies into traditional manufacturing practices. Companies are enhancing their machinery with machine-to-machine (M2M) communication systems and IoT sensors for automated processes and self-monitoring capabilities.
  • Computer vision: A facet of AI and ML that trains computers to interpret and analyze digital images captured by cameras and videos, enabling machines to recognize and categorize objects effectively.
  • Supply chain control tower: A connected and personalized dashboard that provides near-real-time insights into operational metrics and events across the supply chain, allowing manufacturers to address and prioritize operational challenges promptly.

Implementing a Digital Vision

CCI aims to leverage the digital era by investing in data and technology across four crucial areas:

  1. Customer experience
  2. Asset optimization
  3. People experience
  4. Innovation for growth

Focusing on asset optimization, the CCI team partnered with AWS to establish a continuous improvement engine for their manufacturing assets. This initiative aims to minimize equipment downtime through predictive analytics, enhance production line efficiency, and conserve resources such as water and electricity. With the digital twin solution, CCI automated processes in one of its plants, with plans to extend this across all 26 bottling facilities.

CIP Solution Overview

CCI has developed a new clean-in-place (CIP) solution, designed to clean production line interiors without disassembling equipment. This innovation is set to streamline daily cleaning operations, resulting in energy and water savings, better compliance with hygiene regulations, and improved product quality.

Creating the CIP Solution

To build the CIP solution, AWS and CCI needed to gather and process a vast amount of industrial data while developing dynamic data models—a challenging task given the limitations of legacy systems. The team utilized AWS IoT solutions, including AWS IoT SiteWise and AWS IoT Greengrass, to collect data from machinery and processes, presenting insights on user-friendly dashboards. They also implemented Amazon DynamoDB, a fast NoSQL database service, to achieve near real-time visibility of the CIP process, creating digital representations of machinery. Furthermore, AWS IoT Analytics, AWS IoT Core, AWS Lambda, and AWS Glue were deployed to enhance the CIP data in the cloud. The enriched data is stored in an industrial data lake, allowing business users to generate reports using Amazon Athena and Tableau.

Outcomes of the CIP Solution

In just two months, CCI and AWS established the CIP digital twin. Within four months of its rollout, CCI attained significant results:

  • Discovered over 20 optimization points in the cleaning processes.
  • Achieved a 20% reduction in electricity consumption, translating to an estimated annual savings of 156,000 kWatt for 60 systems.
  • Reduced water usage by 9%, forecasting potential annual savings of 90,000 tons across 60 systems.
  • Added 34 days to the production schedule due to an enhanced cleaning process.

Following these remarkable outcomes, CCI expanded the digital twin CIP solution to four plants and incorporated filler-mixer machines in three additional facilities to detect machine failures and boost production line efficiency. CCI is also developing solutions to automate all manufacturing processes to optimize assets, human-machine interactions, line utilization, and sustainability by building a comprehensive digital twin solution in the cloud via AWS.

Bringing It All Together

There’s much more to the Coca-Cola narrative than can be captured in this brief post. For further insights on AWS solutions at Coca-Cola İçecek, make sure to check out the detailed blog post here. Additionally, for authoritative resources on this subject, visit this link. If you’re interested in career opportunities, you can explore this excellent resource.

Location: Amazon IXD – VGT2, 6401 E Howdy Wells Ave, Las Vegas, NV 89115.

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