Industry · FMCG & Manufacturing · Asset Performance Management

Production uptime
is not a maintenance problem.
It's a strategy problem.

Optimal delivers OEE improvement, structured maintenance strategy and ISO 55001 asset management programmes for FMCG and manufacturing operators — from high-speed packaging lines to multi-site consumer goods production and process manufacturing.

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OEE Programme

OEE+

Shift from time-based to condition-led maintenance delivering measurable OEE improvement on high-speed production lines globally

Packaging & Paper

Multi-site

Asset register, maintenance strategy and Optimal360™ OEE monitoring deployed across global packaging and paper manufacturing sites

Standards Applied

ISO 55001

Asset management governance aligned to ISO 55001 across multi-site manufacturing portfolios — from gap assessment to SAMP delivery

High-Speed Packaging Lines

Process Manufacturing

Beverage & Consumer Goods

Paper & Corrugated Packaging

OEE · RCM · ISO 55001 · Optimal360™

Europe · Americas · Middle East · Africa

The Operating Reality

FMCG demands
uncompromising uptime

Fast-moving consumer goods manufacturing operates on some of the tightest margins and highest throughput demands of any industry. A single unplanned line stoppage on a high-speed packaging or filling operation does not just delay production — it creates cascading downstream consequences through supply chain, distribution and customer fulfilment.

The pressure is compounded by frequent product changeovers, rapid line speed demands, hygiene and food safety compliance requirements and a workforce culture where reactive maintenance is accepted as the norm. Getting ahead of failures in this environment requires more than condition monitoring — it requires a structured reliability programme embedded into how the site operates every day.

Optimal brings structured APM methodology to FMCG environments — ISO 55001-aligned, OEE-driven and built for the pace and complexity of consumer goods manufacturing.

Unplanned line stoppages eroding OEE targets High-speed filling, packaging and processing lines experiencing recurring unplanned failures. Root cause analysis absent or inconsistent. OEE tracked but not actively managed through reliability intervention.

Maintenance strategy not linked to asset criticality Time-based PM schedules applied uniformly regardless of asset criticality or failure mode. Critical sealing, labelling and primary packaging equipment treated identically to low-consequence ancillary plant.

CMMS data too poor to support reliability decisions Work orders closed without fault codes. Asset hierarchies incomplete. MTBF and failure trending unavailable. Production line performance data held separately from maintenance records with no integration.

No visibility across multi-site manufacturing portfolio Different sites, different ERP or CMMS systems, different maintenance philosophies. No common performance framework. Best practice identified at one site never transferred to others.

Spares not aligned to line criticality Generic stock policies not linked to failure probability or consequence. Critical fast-wear components causing extended downtime; slow-moving stock consuming working capital unnecessarily.

Our Approach

Reliability engineered
for production pace.

Optimal's approach to FMCG asset performance begins with a structured understanding of your production system — which assets drive OEE, which failure modes are most consequential, and where the gap between current maintenance practice and optimal reliability strategy is widest.

We work alongside your engineering and maintenance teams to design and embed a reliability programme that is practical for a fast-paced production environment — structured enough to drive measurable OEE improvement, lightweight enough to operate at line speed. The ARaaS® framework provides the governance architecture; Optimal360™ delivers the real-time performance visibility.

Asset criticality analysis aligned to OEE impact and failure consequence →

RCM-based maintenance strategy for high-speed production lines →

CMMS data governance and work order quality improvement →

OEE monitoring via Optimal360™ — real-time line performance visibility →

Multi-site performance benchmarking and best practice transfer →

ISO 55001 gap assessment and strategic asset management planning →

ARaaS® Framework

Services Portfolio

What Optimal delivers
in FMCG environments

Full services

OEE Monitoring & Performance Management

Real-time OEE tracking via Optimal360™ platform

Availability, performance and quality loss categorisation

Line-level KPI dashboards and shift reporting

Loss analysis and chronic failure identification

Maintenance Strategy & RCM

FMECA across primary filling, packaging and processing equipment

Asset criticality classification by OEE and safety consequence

RCM task selection and PM schedule optimisation

Maintenance plan integration with production scheduling

Asset Register & CMMS Governance

Production line asset hierarchy development and tagging

Work order quality standards and fault code libraries

SAP PM, Maximo and site-specific CMMS integration

MTBF trending, failure analysis and reliability reporting

Predictive & Condition Monitoring

Vibration, thermography and motor current monitoring for rotating plant

Real-time anomaly detection and early failure signature identification

Prescriptive maintenance recommendations via Optimal360™

Historian and SCADA integration for production data correlation

Spares & Inventory Optimisation

Criticality-led spare parts strategy for production line equipment

Fast-wear consumables profiling and stockholding optimisation

Obsolescence management and OEM rationalisation

Warehouse structure and stock health review

ISO 55001 & Strategic Asset Management

ISO 55001 gap assessment and clause-by-clause maturity scoring

Strategic Asset Management Plan (SAMP) development

Asset management policy, objectives and KPI framework

Multi-site governance structure and certification roadmap

Trusted by Manufacturers

Optimal has delivered asset performance programmes for FMCG and manufacturing operators across Europe, the Americas and Africa — spanning packaging, paper, beverage and consumer goods production.

Global Packaging & Paper Group · Multi-site · Europe & Emerging Markets

Global FMCG Beverage Manufacturer · Multi-site · International

Consumer Goods Manufacturer · Southern Africa

Corrugated Packaging Operator · Multi-site

Detailed case studies below are anonymised in line with Optimal's client confidentiality policy. Client consent is required before specific project details are attributed publicly. Contact us to arrange reference calls with relevant operators.

Case Studies — FMCG & Manufacturing

Proven delivery across
consumer goods manufacturing

All case studies

FMCG · Packaging & Paper · Multi-site

Global Packaging & Paper Group — OEE Monitoring & Asset Management

Optimal360™ Deployment & Maintenance Strategy

A global packaging and paper group operating manufacturing sites across Europe and emerging markets required real-time OEE visibility and a structured maintenance strategy across its primary production lines. Reactive maintenance was the default — no condition monitoring, no consistent failure trending and OEE tracked by operations but not actively managed through reliability intervention.

Results delivered

Optimal360™

Real-time OEE monitoring platform deployed across primary converting and packaging lines — availability, performance and quality losses categorised by shift, line and asset class. Management dashboards live within weeks of deployment

RCM

Criticality-led maintenance strategy developed for converting, cutting and finishing lines. FMECA completed per line type. PM schedules restructured — planned maintenance compliance rate improved and unplanned stoppages reduced on critical assets

FMCG · Beverage · OEE Improvement

Global Beverage Manufacturer — Production Line Reliability Programme

OEE & Maintenance Strategy Development

A global FMCG beverage manufacturer with high-speed filling and packaging operations experiencing chronic unplanned downtime on critical bottling lines. Maintenance practice was calendar-driven with no link to failure consequence or asset criticality. Repeated failures on sealing, capping and labelling equipment causing significant production loss and customer service impact.

Results delivered

Structured

Asset criticality assessment completed across all primary packaging lines. Criticality matrix aligned to OEE impact, food safety consequence and throughput risk. Maintenance strategy revised — critical assets moved to condition-based and predictive tasks

CMMS

Work order quality improvement programme delivered. Fault code library developed per equipment class. MTBF trending enabled for the first time — chronic failure assets identified and targeted for defect elimination

FMCG · ISO 55001 · Asset Management

Consumer Goods Manufacturer — ISO 55001 Gap Assessment

Asset Management System & SAMP Development

A consumer goods manufacturer with no formal asset management system in place. Group operations leadership required ISO 55001 alignment across their manufacturing portfolio — no structured governance, inconsistent maintenance practice between sites and no common KPI framework for asset performance measurement.

Results delivered

ISO 55001

Clause-by-clause gap assessment completed across three manufacturing sites. Maturity scored across Leadership, Planning, Support, Operation, Performance Evaluation and Improvement. Prioritised action plan with resource and timeline requirements delivered

SAMP

Strategic Asset Management Plan developed — asset management policy, objectives, KPI framework and 3-year roadmap to ISO 55001 compliance defined. Common governance structure agreed across all sites

FMCG · Spares · Inventory

Packaging Manufacturer — Spares Optimisation Programme

Inventory Rationalisation & Criticality-led Stockholding

Packaging manufacturer carrying excessive spare parts inventory — high working capital tied up in slow-moving and obsolete stock, while critical fast-wear components on primary converting lines were causing extended MTTR due to procurement lead times. No structured criticality-led spare parts policy in place.

Results delivered

Rationalised

Full spare parts audit completed. Slow-moving and obsolete items identified for disposal or return. Working capital reduction achieved through structured stock rationalisation programme

Criticality-led

Min/max stockholding levels set by failure probability, consequence and supplier lead time. Critical fast-wear components profiled. Stockout risk eliminated on five high-consequence equipment classes

FMCG · Predictive · Digital

Process Manufacturer — Predictive Maintenance Deployment

Condition Monitoring & Optimal360™ Integration

A process manufacturing operator with recurring unplanned failures on critical rotating plant — pumps, mixers and conveying systems causing production stoppages and product quality events. No condition monitoring programme and calendar-based PM schedules missing the actual failure modes occurring in service.

Results delivered

Predictive

Vibration analysis and thermography programme designed and deployed on critical rotating assets. Optimal360™ integrated with existing historian — anomaly detection live within eight weeks of programme start

Early Warning

Three major failure events predicted and planned interventions completed before production impact. Average failure detection lead time: 14 days ahead of functional failure. Reactive to planned ratio improved significantly within six months

Digital Engineering

From production data
to line performance decisions

Manufacturing operations generate more data than most — SCADA, historian, MES, CMMS, quality records. The challenge is not data availability. It is the ability to convert raw production and maintenance data into decisions that improve line reliability, reduce unplanned downtime and compound OEE performance year on year.

Optimal360™ provides the platform layer that connects your operational data to maintenance decision-making — without replacing your existing systems. It sits above your historian, SCADA and CMMS to deliver the real-time performance visibility and failure intelligence your engineering team needs to operate proactively.

Real-time OEE by line, shift and asset class →

Automated anomaly detection on critical production plant →

Maintenance KPI tracking — planned compliance, MTBF, backlog →

Multi-site portfolio benchmarking and best practice identification →

Integration with SAP, Maximo, historian and SCADA environments →

Predictive maintenance services

Digital manufacturing and predictive maintenance technology

Production uptime
is not a maintenance problem.
It's a strategy problem.

FMCG demands
uncompromising uptime

Reliability engineered
for production pace.

What Optimal delivers
in FMCG environments

OEE visibility
without complexity.

Proven delivery across
consumer goods manufacturing

From production data
to line performance decisions

How does your manufacturing operation
compare against global peers?

Ready to move from
reactive to reliable?

Optimal across
asset-intensive sectors

Production uptimeis not a maintenance problem.It's a strategy problem.

FMCG demandsuncompromising uptime

Reliability engineeredfor production pace.

What Optimal deliversin FMCG environments

OEE visibilitywithout complexity.

Proven delivery acrossconsumer goods manufacturing

From production datato line performance decisions

How does your manufacturing operationcompare against global peers?

Ready to move fromreactive to reliable?

Optimal acrossasset-intensive sectors

Production uptime
is not a maintenance problem.
It's a strategy problem.

FMCG demands
uncompromising uptime

Reliability engineered
for production pace.

What Optimal delivers
in FMCG environments

OEE visibility
without complexity.

Proven delivery across
consumer goods manufacturing

From production data
to line performance decisions

How does your manufacturing operation
compare against global peers?

Ready to move from
reactive to reliable?

Optimal across
asset-intensive sectors