Case Study
How Corticeira Amorim Saved €26M with TrakSYS
Corticeira Amorim saved over €26 million by optimizing inventory levels across its 25 global facilities.
TrakSYS improved OEE by 5 to 10 points at each of Amorim's 25 production sites.
Amorim achieved its paperless goals, eliminating paper-based record keeping across its facilities.
In the past, records were made on paper by an operator, then transcribed into the ERP by someone else, sometimes days or weeks later. That meant the people running the business never had real-time access to the data they needed.
The Company
Corticeira Amorim is the largest cork processing group in the world. Founded in 1870, the company has dozens of business units spread across five continents, exports products to more than 100 countries, and serves a diversified network of 27,000 customers. Now in its fourth generation of family leadership, Corticeira Amorim invests millions of euros annually in R&D, makes 94% of its sales outside Portugal, and employs more than 4,400 people.
With an eclectic and growing product portfolio, ranging from wine and champagne stoppers to space-grade materials, the Amorim team needed a system agile enough to optimize production across its many facilities while remaining versatile enough to adapt to each site's unique needs. Parsec Automation, LLC certified partner Kaizen Tech introduced Amorim to TrakSYS to meet that need.
The Challenge
Amorim's plants lacked shop floor visibility and had no efficient system for root-cause analysis. The team had little insight into true inventory levels, relied heavily on paper-based record keeping, and depended on manual production processes and data entry across its facilities.
The Solution
Kaizen Tech piloted TrakSYS at one of Amorim's Champagne cork stopper facilities before rolling the platform out across the company's 25 global production sites. The Production Management module increased the efficiency and speed of production runs, and gave operators the ability to monitor material consumption in real time for the first time.
TrakSYS' Inventory Management solution improved raw material ordering and warehousing, and as scrap and reject decreased, teams were able to stop over-ordering and overpaying for raw materials. The real-time, contextualized data let Amorim move cost analysis reporting to the start of each month instead of the middle, giving teams more runway to make corrective changes to production schedules. Batch and Recipe Management, integrated with Amorim's ERP system, let TrakSYS automatically select and cue the right recipe whenever a new customer order triggered production, reducing errors from manual recipe entry and enabling end-to-end traceability.
Amorim and Kaizen Tech have since begun introducing TrakSYS Algorithmic Production Scheduling and statistical process control to each of the 25 global facilities.
The Impact
Corticeira Amorim has saved more than €26 million by optimizing inventory levels and improved OEE by 5 to 10 points across each of its 25 facilities. The company has achieved its paperless goals by eliminating paper from the factory floor, established complete end-to-end traceability across every facility, and improved its on-time and in-full delivery metrics.
Preventing costly quality issues has saved several million additional euros and boosted profitability across the business.
See Exactly How it Works
Get the full case study, including Corticeira Amorim's TrakSYS solution architecture and results across its 25 global facilities.
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