Factory Simulation in

Tetra Pak PM
Jonas Frjd
2015-10-05

Internal
JF, 2015-10-05

A package should save

more than it costs

Internal
JF, 2015-10-05

Key success factors

Industrial
scale

Aseptic
technology

Paper based
material

End-to-End
responsibility

World wide
availability
Internal
JF, 2015-10-05

Todays package portfolio

Internal
JF, 2015-10-05

Carton packages sold 1980 - 2015

~180 billion packages sold 2014

Mio
packs

200 000
180 000
160 000
140 000
120 000
100 000
80 000
60 000
40 000
20 000
0

'80'81'82'83'84'85'86'87'88'89'90'91'92'93'94'95'96'97'98'99'00'01'02'03'04'05'06'07'08'09'10'11'12 13 14

Internal
JF, 2015-10-05

Tetra Pak Global Business Model

Three independent businesses

Capital Equipment

Technical Service

Packaging Material

Internal
JF, 2015-10-05

Introduction to Packaging Material

Where are we in the value chain?

Dairy farms

Paperboard
manufacturing

Base
materials

Converting

Milk distribution

Product processing

Transport

Product
distribution

Product
sale

Consumer

Product
packaging

Additional
materials
Recycler

Internal
JF, 2015-10-05

Introduction to Packaging Material

Two systems

Packaging Material

Converting

Internal
JF, 2015-10-05

Packaging Material Factories

- 33 locations

Internal
JF, 2015-10-05

Introduction to Packaging Material

Converting System

Printing

Lamination

Finishing

Internal
JF, 2015-10-05

Internal
JF, 2015-10-05

Introduction to Packaging Material

Meeting customer demand vs. Managing Complexity
Many

different customers
Different packages
Different package sizes
Different openings
Different printing techniques
Different liquids require different packaging
materials

Internal
JF, 2015-10-05

How do we apply simulations?

Internal
JF, 2015-10-05

How do we apply simulations?

Understand different needs
Business
Cases for new
projects?

How do we allocate
products to our 33
factories?

How can we
minimise the setup
losses in our
factory?

How much can our

factory produce?

Factory

Marketing & Product

Management

Simulations?
How do we screen
new ideas?
How can we test our
design & solutions in a
real environment?

Engineers
Internal
JF, 2015-10-05

Operational

Strategic

Identified areas of use of Factory Simulation in

Packaging Material
Development

Production

Verification of project
business case for
project prioritization

Allocation strategy &

Asset optimisation

Design development
support & verification

Continuous
Improvement in
Manufacturing

Internal
JF, 2015-10-05

Factory Simulation shows

behaviour in our factories
We build
detailed models
of our factories
We use real
production data
to validate
models
We use
synthetic data
to simulate
scenarios
We analyze
KPI:s and
bottle-necks

We simulate order
mixes and see the
consequences

We screen new
technologies

We verify
solutions before
investing
Internal
JF, 2015-10-05

Factory Simulations: what is it?

Internal
JF, 2015-10-05

Internal
JF, 2015-10-05

Operational

Strategic

Identified areas of use of Factory Simulation

in Packaging Material
Development

Production

Verification of project
business case for
project prioritization

Allocation strategy &

Asset optimisation

Design development
support & verification

Continuous
Improvement in
Manufacturing

Internal
JF, 2015-10-05

Greatest challenge right now

- Increase availability of the tool

Internal
JF, 2015-10-05

Greatest challenge right now

- Increase availability of the tool

Version management
Robustness
User friendliness

Internal
JF, 2015-10-05

Factory Simulation Process Flow

Specifications
Improved version management
Verification & validation strategy

Data input

Data processing

Data storage for

simulation purpose

Simulation Simulation
Internal
model
output
JF, 2015-10-05

Factory simulation has displayed great value to Tetra Pak

Sharp tool for detailed studies
Need to increase availability of Factory Simulation as a tool and
increase leverage of our models

Internal
JF, 2015-10-05