Reduce, Reuse, Raizen: Production Optimization at Raizen

Among the largest private companies in Brazil, with over 40,000 employees and 15,000 business partners nationwide, Raizen is a leader in global bioenergy and green power, driving energy transition and redefining the future of energy. Raizen's business includes the manufacture and sale of renewable energy and sugar from sugarcane, with worldwide distribution.

With customer demand continuing to rise, the team at Raizen's Sao Paulo facility was grappling with capacity constraints. As a business that prizes sustainability, the team realized they needed to apply that same mindset to solve their operational challenges.

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Production was primarily tracked through manual processes and data collection, with OEE calculated manually, leading to delayed results. Root causes of less-than-ideal OEE were undeterminable, solutions were based on paper and Excel sheets only, and Raizen needed to increase production volume without incurring capital expenditure.

Hoping to work with an integrator that would help them achieve their goals and guide teams toward a path of continuous improvement, Raizen reached out to Parsec Automation, LLC partner Cimlogic, part of the ITI Group. Aware of Raizen's goals and eager to help the energy provider elevate its operation, the team at Cimlogic recommended implementing TrakSYS.

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Through implementing TrakSYS for Performance Management, Raizen gained the ability to accurately monitor production and OEE in real time. Calculating performance and availability data via a single counter value per line, teams can now instantly determine if a line is running, how fast it is running, and how many units have been produced. Facility-wide TVs, dashboards, and signs now actively display production statuses and Raizen's OEE percentage.

Utilizing TrakSYS, Raizen was able to create a company-wide culture of continuous improvement, going from 42% OEE at the start to an average of 63%, with some lines achieving 75%. The team created a business case for other initiatives and investments, and achieved in 11 months what used to take 12.

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Raizen met its goal of going paperless, reduced operational costs by upwards of 8%, and gained increases in operational flexibility. Looking ahead, Raizen is considering introducing TrakSYS to other areas of its facility to further the results achieved in its filling and packaging areas.