Transforming Papa Johns’ Dough Production with Proficy® Smart Factory Cloud MES, a Hosted SaaS Solution

Customer Story Bar

Data Accuracy and Traceability

Capture and track production data in real-time

Operational Efficiency

Identify and address equipment downtime issues

Minimized IT investment

No added infrastructure or IT resource expenses

Customer Story Bar

Background:

Papa Johns’ is a major pizza franchise based in the U.S. Papa Johns’ Food Service (PJFS) faced significant operational challenges in their dough production and distribution process. Dough production takes place at eleven Quality Control Centers (QCC) geographically dispersed across the United States. This story is about the QCC in Freedom, Pennsylvania, the first of an 11-site enterprise MES initiative.

With a network of 185 stores across seven states, ensuring timely and accurate delivery of the highest-quality fresh dough and other ingredients from the Pennsylvania-based QCC to stores was critical. The implementation of GE Vernova’s Proficy® Smart Factory hosted cloud-based Manufacturing Execution System (MES) revolutionized their operations, addressing key challenges and delivering substantial outcomes.
GE Vernova
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Challenges

Manual Processes and Human Error:
  • Prior to Proficy® Smart Factory Cloud MES, PJFS relied on paper-based systems for tracking batches, ingredient usage, and production data. This manual approach was prone to human error, making it difficult to ensure data accuracy and traceability.
  • The paper-based system also made it challenging to analyze data effectively, leading to inefficiencies and potential delays in addressing issues.
Lack of Real-Time Data:
  • Without real-time data, PJFS struggled to monitor production processes and equipment performance. This lack of visibility hindered their ability to make timely decisions and address issues promptly.
  • The absence of real-time alerts meant that deviations from specifications could go unnoticed until the end of the day, impacting product quality and consistency.
Operational Inefficiencies:
  • The manual system required significant time and effort to track and manage production data, leading to operational inefficiencies.
  • The inability to integrate data from different systems further complicated the process, making it difficult to optimize production and reduce waste.
Minimizing costs and IT resources required to digitally transform:
  • PJFS desired to leverage the benefits of an MES, but taking on and maintaining the infrastructure and IT resources required to do so and keep the system secure and updated seemed both cost-preventative and overwhelming.

Results:

Outcomes with Proficy Cloud MES
Enhanced Data Accuracy and Traceability:
  • Proficy® Smart Factory Cloud MES provided PJFS with a digital platform to capture and track production data in real-time. This reduced the need for manual data entry and significantly reduced the risk of human error.
  • The system ensured 100% traceability of ingredients and batches, enabling PJFS to quickly identify and address any issues that arose during production.
Real-Time Monitoring and Alerts:
  • With Proficy® Smart Factory Cloud MES, PJFS gained real-time visibility into their production processes and equipment performance. The system provided immediate alerts for any deviations from specifications, allowing for prompt corrective actions.
  • This real-time monitoring capability improved product quality and consistency, ensuring that each batch of dough met Papa John's high standards.

“MES gives us the ability to see that every day and in real time, because we can see if something doesn't match correctly right away, and we get an alarm. We're now able to address it at that moment. So that's been a big improvement for us from prior methods.”

Cory DeAngelo

Director of Operations

Operational Efficiency and Waste Reduction:
  • Proficy® Smart Factory Cloud MES streamlined PJFS's production processes by integrating data from various systems, including their warehouse management system. This integration enabled more efficient planning, scheduling, and execution of production tasks.
  • The system also helped PJFS identify and address equipment downtime issues, reducing production delays and minimizing waste. By tracking ingredient usage and production yields in real-time, PJFS was able to optimize their processes and reduce waste. “We can keep an eye on quality a lot closer than we could in the past with paperwork.” – Cody Plane, Production Supervisor
Data-Driven Decision Making:
  • The implementation of Proficy® Smart Factory Cloud MES transformed PJFS into a data-driven organization. Access to real-time data enabled them to make informed decisions based on factual information rather than intuition.
  • This data-driven approach improved strategic decision-making, allowing PJFS to optimize their operations and enhance overall efficiency. “I think the outcome of this MES system is it will make us more data driven, and that we will make better decisions strategically because we're going to use data to make those decisions, not just gut feelings or guessing.” – Cory DeAngelo, Director of Operations
Improved Change Management:
  • The transition to Proficy® Smart Factory Cloud MES required effective change management to ensure a smooth implementation. PJFS focused on communicating the benefits of the new system to their team and providing comprehensive role-based training.
  • The support from GE Vernova and GrayMatter Systems during the deployment process was crucial in addressing any issues and ensuring the system's success.
Minimized IT investment:
  • Implementing Proficy® Smart Factory Cloud MES from GE Vernova enabled PJFS to keep their Cap-Ex investments into infrastructure and IT resources flat by investing in a hosted SaaS solution. At the same time, resources were also maximized by leveraging GE Vernova to monitor their system for them, thereby ensuring it remains available and secure, and is maintained and updated over time.
  • By moving forward with a SaaS hosted cloud MES, PJFS now has visibility to data from anywhere at any time instead of on paper on the plant floor only. Additionally, no infrastructure or IT resource expenses were incurred.

“We don’t have a lot of resources at the plant level to manage servers and all that kind of stuff, so a cloud-based solution was a practical and financially sound way to go.”

Cory DeAngelo

Director of Operations

Key Takeaways

Papa John's Food Service's first QCC site success story with Proficy® Smart Factory Cloud MES learnings
Embrace Digital Transformation:
  • Transitioning from manual, paper-based systems to digital solutions like MES can significantly enhance operational efficiency and accuracy.
  • Real-time data capture and monitoring are crucial for making informed decisions and addressing issues promptly.
Improve Data Accuracy and Traceability:
  • Digital systems reduce the risk of human error and help ensure 100% traceability of ingredients and production batches.
  • Accurate data helps in quickly identifying and resolving problems, maintaining product quality and consistency.
Enhance Operational Efficiency:
  • Integrating Proficy® Smart Factory Cloud MES with other systems, such as warehouse management, streamlines production processes and reduces downtime.
  • Real-time monitoring and alerts enable prompt corrective actions, minimizing waste and optimizing resources.
Leverage Data for Strategic Decision Making:
  • Access to real-time data transforms decision-making from intuition-based to data-driven, improving strategic planning and operational outcomes.
  • Data-driven decisions help optimize processes and costs for better efficiency and profitability.
Effective Change Management:
  • Successful implementation of digital solutions requires effective change management, including clear communication, comprehensive training, employee buy-in and prompt support for resolution of issues.
  • Engaging and supporting the team throughout the transition ensures smoother solution adoption and maximizes the benefits of the new system.
Collaborate with Technology Partners:
  • Partnering with reliable technology providers, like GE Vernova and GrayMatter Systems, ensures responsive support and successful deployment of digital solutions.
  • Collaboration with technology experts helps in addressing issues promptly and leveraging their expertise for continuous improvement.
Cloud-based hosted solutions enable flexibility and cost savings:
  • By leveraging GE Vernova’s Proficy® Smart Factory cloud MES, infrastructure and IT resource expenses can be avoided, preserving Cap-Ex budget.
  • Hosted SaaS solutions are monitored and maintained by GE Vernova, ensuring optimal uptime, security and performance while simultaneously eliminating the need to maintain updates and upgrades.

Conclusion

The implementation of Proficy Smart Factory Cloud MES from GE Vernova at Papa John's Food Service has been a game-changer, addressing critical challenges and delivering significant outcomes. By enhancing data accuracy, providing real-time monitoring, improving operational efficiency, and enabling data-driven decision-making, Proficy Smart Factory Cloud MES has transformed PJFS's QCC dough production process in Pennsylvania. By focusing on these key areas, other QCC sites are expected to achieve similar success in their digital transformation journey. This will further enhance operational efficiency, product quality, and PJFS’ overall business performance. This success story highlights the importance of digital transformation for Papa Johns’ and the value of Proficy® Smart Factory Cloud MES in achieving operational excellence.