Case Study
A Taste of Portugal: How Gallo Modernized Production Planning with TrakSYS
TrakSYS gave Gallo real-time visibility into the shop floor, reducing misunderstandings between production areas and shift changeovers.
Actemium designed the TrakSYS deployment to automate Gallo's production scheduling and stock control using real-time data.
TrakSYS helped Gallo digitalize paper-based record-keeping and improve operator engagement across the plant.
TrakSYS was the starting point of data collection for Gallo, and that's important. The platform allowed us to show real-time data to all team members, and its interoperability let us tie into our existing PLCs to automate downtime reporting.
The Company
Founded in Portugal in 1919 by Victor Guedes, Gallo is synonymous with Portuguese soul and tradition. Gallo is currently the number-one Portuguese olive oil brand in the world and the fourth in the world ranking, with a reputation built on quality and a constant search for new knowledge.
The Challenge
With demand for its 500-plus award-winning olive oils only increasing, Gallo needed to streamline and optimize its operation. The company had no efficient method for measuring downtimes, and operators lacked the insights, trends, and real-time KPIs needed to work effectively.
Manual Excel calculations consumed valuable time, production planning and stock forecasting were done manually with minimal real-time context, and disparate ERP and PLC implementations left production teams without the real-time insight they needed. Shop floor teams and supervisors were also hesitant to adopt another software solution.
The Solution
Actemium architected Gallo's TrakSYS deployment to maximize the impact of the company's existing infrastructure, tying TrakSYS into the ERP system (SAP) and Gallo's PLCs to streamline production planning and scheduling. Through user-friendly dashboards, operators gained the ability to start and stop production orders and view KPIs and downtime reports.
Andon Boards placed throughout the factory displayed real-time KPIs and PO statuses, while TrakSYS-backed alerts notified operators when POs were missing required details and production-focused emails kept all appropriate parties informed.
The Impact
Utilizing TrakSYS, Gallo established real-time visibility into the shop floor, optimized KPI monitoring, and designed user-friendly, facility-wide dashboards.
The company also established streamlined, informed communication between shifts, lines, and crews, improved operator impact, efficiency, and engagement, reduced the use of paper on the shop floor, and optimized production planning and scheduling.
Get the Full Gallo Story
See how TrakSYS helped Gallo modernize production planning, cut paper on the shop floor, and gain real-time visibility.
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