How Mondelez Reduced Waste by 59% and Unlocked $1.5M in Annual Value with Real-Time Shop Floor Visibility
Client
Industry:
Food & Beverage Manufacturing
Built-In Value:
Waste Reduction, Operational Accountability, Real-Time Visibility
Machines
Connected:
Reading time:
~5 minutes
Tighter margins, higher quality standards, sustainability mandates, and increasing complexity on the plant floor. Mondelez chose not to wait.
As part of a global digital transformation, the company set bold goals — zero waste, 100% employee adoption, and a factory of the future powered by real-time data. But achieving those goals required more than ERP and quality systems alone.
That’s where Shoplogix came in.
Mondelez launched a large-scale Integrated Digital Factory (IDF) strategy to unify ERP, quality, and enterprise systems across its global operations. The vision was clear: transparency, efficiency, and continuous improvement.
But in practice, a critical gap emerged.
Despite having enterprise systems in place, the company could not reliably see what was happening on the plant floor in real time. Production data was incomplete, inconsistent, or delayed — making it nearly impossible to act quickly or accurately.
In one facility alone, early data revealed 8.3 hours of lost production per week, hidden in plain sight.
Operators couldn’t see issues as they happened, so problems lingered
Slow-running lines and excessive changeovers went unchecked
Waste reached 1.57%, costing approximately $1.1M annually
Teams lacked benchmarks to compare current runs vs. past performance
Root cause analysis relied on assumptions, not facts
Minor stops accumulated into major losses
Average 25 days between next run (DBNR) created unnecessary downtime
After evaluating 30 different solutions, Mondelez selected Shoplogix Smart Factory Suite to complete its IDF strategy.
Why Shoplogix?
Because it connects directly to machines, delivers real-time operational visibility, and empowers operators, supervisors, and leadership with the same trusted data — instantly.
The platform was intuitive enough to drive operator adoption, not just executive reporting.
Automated data collection displayed live on the plant floor — eliminating manual reporting and guesswork.
Accurate historical data enabled true root cause analysis, smarter preventative maintenance, and CapEx justification.
Seamless integration with ERP and Integrated Quality Systems (IQS), eliminating duplicate data entry and human error.
Shoplogix reduced implementation time by over 75%, from 13 months to just 3 months per site.
Accurate, accessible data transformed decision-making, from reactive to proactive, from assumptions to action.
You can’t improve what you can’t see
ERP and quality systems need a real-time execution layer
Operator visibility drives accountability and engagement
Fast time-to-value matters in large-scale transformations
Standardized metrics unlock scalable continuous improvement
Many manufacturers invest heavily in enterprise systems but still struggle on the plant floor. Shoplogix bridges that gap — connecting machines, people, and systems to turn insight into action.
Whether your goal is waste reduction, OEE improvement, sustainability, or team alignment, real-time visibility is the foundation.
With Shoplogix embedded into its global operations, Mondelez continues advancing its vision of a consumer-driven, responsive, and autonomous factory of the future, where every shift, every line, and every team operates with clarity and confidence.
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