Dr Garry Menz Brewing Area Manager
Yatala Brewery, Queensland, Australia
Practical Continuous Improvement
in a Filter Room
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Outline
• IBD Master Brewer
• The Challenge
• The Solution
• The Results
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IBD Master Brewer
• 5 Modules
• 4 exam sets + practical project
• Module 1 – Raw Materials & Wort Production
• Module 2 – Fermentation & Beer Processing
• Module 3 – Packaging of Beer
• Module 4 – Resource Management & Regulatory Compliance
• Module 5 – Practical Project Dissertation
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Yatala Brewery, Queensland, Australia
• 4 million hL/year
• 25 beers
• Cider, RTDs, spirits
• Six pack lines
• Filter room
– Two filter lines
– Three DE candle filters
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THE CHALLENGE
Downtime to Packaging
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Downtime to Packaging • Increasing downtime to packaging lines due to beer not available in time
• 2014/15 peak to 2015/16 peak, 3.5x increase
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Understanding the Problem
• Brainstorming using fishbone tool
• Review recent production
• Data collection & analysis
• Determine impact of each
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5 %
7 %
4 %
Understanding the Problem
• Increased production volumes not being matched by increased filter room
output
• Need to increase filter room output. Time to go shopping! More tanks!
– Three options to increase throughput
– $2 - $10 million (est.)
– Couldn’t e operational efore peak
• Fix what we have!
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THE SOLUTION
Optimise the Filter Room
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What Can We Fix?
• Discussions with operators
• Time spent on the job to understand efficiency drivers
• Ask and understand Why?
• Dig into instances of downtime (3Qs, 5 Whys)
• All ideas recorded and prioritised in electronic scrapbook (MS OneNote)
• One improvement unlocks two more
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What Did We Fix?
• Removed recurring faults
• Reduced filter turnaround & brand change time
• Improved DE dosing control
• Improved right first time
• Improved filterability of dry-hopped beer
• Optimised dilution
• Reduced downtime from trap filtration
• Reduced downtime from stabilisation
• Improved planning
• Improved performance measurement
• Improved filter run lengths
• …..et . • Communication across three shifts – 14 filter operators
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SIMPLIFY
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Example 1 – Why So Complex? • Low filter room output on flavoured beer, highly hopped beer
• What CIPs/flushes are required between beers? Flavoured beer to standard lager? Dry
hopped beer to standard lager?
– Reconfigure flavour dosing to reduce CIPs required
– Verified what cleans are required
• Was, CIP everything to be sure Now, clean what we need to how we need to
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4 SOPs into one page
Example 2 – Why So Complex? Trap Filters
• Problem: Various revisions of the same SOP existed for cartridge flushing
• Solution:
– Flushing regime optimised with OEM
– Consolidated four ays into est SOP
– Legacy HMI cycles decommissioned to simplify
– Valve labeling improved to simplify
• 45 minutes additional production time per day for each filter line
• Reduced water use
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VISUALISE
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Example 3 – DE Dosing, Now I See It!
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Different
filters have
different max
shell pressure
Real time
visual
indicator of
performance
GET THE BASICS RIGHT
& STANDARDISE
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Example 4 – Dry Hops & Candle Filters
• Slurry post-separator
• Hop particles blinding candle filters
• Unpredictable
– sometimes ok, sometimes not
– an’t plan
• Implemented cropping regime with
check sheets and coaching
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p = 0.004
UNLOCK EXISTING POTENTIAL
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Example 5 – Turn it to 100 %
• Filtration is at high gravity, with pre-dilution for high dilution products
• Determine the limiting factor (pinch point)
– Post dilution was being limited not by dilution liquor supply but by ranging on
flow meter (increased from 300 to 350 hL/hr)
– Consider downstream pumps, pressures, instrumentation etc.
• Optimise balance between pre vs post dilution
• Increased production by 4.5 %
– Filter less water
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MAKE YOUR AUTOMATION WORK
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Example 6 – Remove Frustration
• Multiple minor edits to PLC ladder logic
• Returning to standard – Horizontal leaf filter ouldn’t e used at full apa ity
• CIP not used, doesn’t ork – Minor code error fixed
– Lo le el s it h on one post filter uffer tank faulty • Due to tank outlet design
• Modified PLC code
• Removed recurring faults – Dosing tank running empty
– Filter high pressure coding
• Improved visuals – Display live integrated DO per BBT
– Improved visualisation of faults on BBTs
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THE RESULTS
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Impact on People
• A better place to be!
• Stop accepting recurring problems
• Question the status quo
• Look for ways to improve
• Improvement culture is catchy
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Through Continuous
Improvement Activities
• Improved culture
• 90 % reduction in downtime to packaging from no beer supply
• Improved supply chain stability & confidence
• Reduced water and utility use
• Significant cost savings
• Reduced diatomaceous earth use
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