Success Stories: Food and Pharmaceutical

Catania Oils

Ayer, Massachusetts

Catania Oils Product Line

About Catania Oils

Project Summary

Catania Oils is a leading provider of conventional,

Catania Oils knew they needed help in leveraging their data.

non-GMO Project verified and organic oils for theingredients, foodservice, and retail markets. Thecompany is driven by their steadfast commitment toexcellence and continuous improvement processes
that deliver the highest quality of vegetable, olive,
and blended oils to the industry and its customers
around the world. The company operates a high-techmanufacturing facility, a large distribution center, aquality assurance (QA) laboratory, a railroad and bulk
processing area as well as multiple automatic productionlines. In addition, Catania Oils also operates a fleet oftank and box trucks, allowing them to service customers
throughout the United States.

Operations Dashboard

Specifically, they needed to zero in on the informational insight that this data could provide for plantwide visualization
into production. In particular, the company wanted:•To know the status of their lines - which lines areup and which lines are down.

•To know the quantity of resources being used specifically to know the tank levels to be able toorder raw materials based on the availability ofstorage space.

•To identify potential efficiency gains in their
manufacturing processes so wanted to be able toinvestigate overall equipment efficiency (OEE) andto measure KPI performance.

Tank Level Overview

Food and PharmaceuticalSuccess Stories: Food and Pharmaceutical•

To have the capability of batch management andmaterial handling.

•To track the quantity of additives for regulatory
purposes.

•To know the quantity of manufactured products.

They therefore set out to look for an automation softwarethat could capture the data and display it in a meaningful
way for them to make data-driven decisions.
Catania Oils was introduced to system integrator Data
Acuity, and as a longtime partner of ICONICS, Data Acuity
chose ICONICS for the system automation software.
Located in Hampton, New Hampshire, Data Acuity is
an automation software company that focuses on themanufacturing, energy, and service delivery efficiency

for Automated Systems. Their consulting services, thetechnologies they represent, and their engineering design
efforts are all centered on focusing their clients’ resources
on areas that will bring the greatest efficiency gains.

ICONICS Products Deployed
The following ICONICS products were deployed:•web-based real-time HMI/SCADA suite with•ICONICS
high-speed,reliable, robust plant data historian

By using ICONICS solutions, Catania Oils saw
immediate value.

Pump and Rail Operations

Realized Real-Time Benefits
ICONICS software allowed Catania Oils to monitor overall
equipment effectiveness (OEE) and loss deployment toimprove production efficiency. The key was to focus theright resources on the right problems and to use OEE
for gaining insight. As a metric, OEE provided a clear
understanding of the difference between the quantityof sellable product that could be made versus the actual
quantity of product that was made. The primary insightgained from this metric was a full understanding of
which resources needed to be assigned to which priorityproblems. Using ICONICS, Catania Oils could measureproduction efficiency by breaking OEE into three separate
buckets and measuring these aspects: availability,performance, and quality.
Additionally, the company was also able to make gains
in efficiency by monitoring loss of deployment. Using
ICONICS software, Catania Oils could determine howmuch product was actually made; what was the lossof efficiency that could be attributed to the fault of amachine or an asset; and what was the loss of efficiency
that could be attributed to the process around the asset.
By monitoring OEE and loss deployment, Catania Oils
gained even greater insight into the potential loss ofefficiency. The company was able to focus on the entire
process as opposed to focusing on a single machine fault
or quality defect. Catania Oils could therefore capitalize
on even greater efficiency gains.

Operations Pareto Chart/Loss Deployment Pie Chart

Food and PharmaceuticalSuccess Stories: Food and PharmaceuticalConclusion
Catania Oils will continue to use ICONICS’ software tooptimize their operations and are now using the software
to look into predictive maintenance. They are correlating
their production information with the CMMS system inorder to schedule maintenance actions predictively as
opposed to scheduling maintenance actions based on acalendar. The company plans to continue to grow theirexpertise and experience in using ICONICS’ software forcontinuous improvement into their operations.

collect data regularly through“ WeICONICS. And so, we get data fromevery line, from every product, and fromevery shift, and that data is accumulated
in the database and a report comes out
every day for us to be able to determine
how each one of those lines is running.

”Dan Bracket,

Vice President of Operations

Palletizing Conveyor Operations

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Food and Pharmaceutical