Las instalaciones se convirtieron en las más grandes de la región Asia-Pacífico cuando The Coca-Cola Company (TCCC) confirmó una inversión total valuada en aproximadamente 500 millones de dólares en marzo de 2015 . En años recientes, Coca-Cola ha invertido más de 1200 millones de dólares en Indonesia , un mercado dinámico y en rápido crecimiento. Con una población de 260 millones de personas, el país se posiciona en cuarto lugar en el mundo por la cantidad de habitantes, con una importante clase media emergente que consume bajos niveles de bebidas sin alcohol.
Coca-Cola Amatil Indonesia (CCAI) fue fundada en 1992. La empresa fabrica y distribuye bebidas sin alcohol y listas para beber en Indonesia, donde opera como una subsidiaria de Coca-Cola Amatil Ltd (CCA), la filial australiana del productor de bebidas estadounidense The Coca-Cola Company. La compañía produce bebidas gaseosas, bebidas sin gas, como jugos, tés, agua y bebidas energizantes e isotónicas, entre otras, en diversos formatos y tamaños de envasado. Sus productos se ofrecen a través de establecimientos minoristas grandes y pequeños, incluidos los supermercados, los minimercados y las tiendas tradicionales, además de mayoristas.
La planta de Cikedokan produce bebidas gaseosas, té y jugos en botellas de PET y té en vasos de plástico. Este último formato es muy frecuente en los mercados asiáticos, incluido el de Indonesia. Los vasos son la máxima representación de un formato para el consumo en movimiento, ya que proporcionan, efectivamente, una bebida que se termina en una sola vez. Este tamaño es cómodo para un estilo de vida ajetreado (por lo general, este té se consume en la calle) y tiene el precio ideal para los usuarios de recursos bajos a medios.
El diseño original, que se construyó con equipos de diversos proveedores, contaba con un paletizado manual en su fin de línea, lo que ocasionaba muchos problemas de congestiones, de seguridad y de relaciones entre el personal y la dirección; asimismo, se requería de una gran cantidad de trabajadores eventuales para ejecutar la tarea. «Este trabajo causa mucho calor y es difícil», explicó Grant McClean, gerente técnico para los Proyectos de Capital de la planta. «En todo caso, asegurarnos de que la labor se puede ejecutar de manera segura presenta sus desafíos». Así, comenzaron a buscar una solución de paletizado automático que permitiera disponer de una línea de producción continua con un uso más eficiente de la mano de obra.
«Por supuesto, en Indonesia lo que valoramos mucho en un proveedor de maquinaria es la calidad de los equipos y el hecho de que nos pueda suministrar sus capacidades en ingeniería durante el proceso de la venta para que descubramos la mejor maquinaria y la mejor solución».
Los ingenieros de Gebo Cermex, en estrecha colaboración con el equipo de trabajo en la planta del cliente, diseñaron una nueva solución de paletizado automático personalizada para adaptarse a las necesidades de Cikedokan, que comprende paletizadores capa por capa, transportadores de palés y una enfajadora para cubrir los pálets cargados.
Debido al objetivo —adaptar la línea de producción para entregar 3600 cajas por hora— se consideró que un sistema de tres paletizadores pequeños, uno para cada área de envasado, conectados por un sistema de vehículo sin conductor, sería la solución de fin de línea más rentable y eficiente desde el punto de vista operativo. El vehículo formaba parte de la solución propuesta por Gebo Cermex, que reconoce los beneficios aportados en cuanto a la reducción del tráfico de los elevadores de horquilla, y aumenta de esta manera la seguridad de la planta.
Los tres paletizadores suministrados por Gebo Cermex tienen forma de U: la alimentación de los palés vacíos y la salida de los palés llenos se encuentran del mismo lado de la máquina. El sistema de vehículo transporta continuamente los palés cargados a un transportador, donde se los enfaja antes de llevarlos a los elevadores de horquillas que los esperan. Luego, se los traslada para su despacho a los depósitos de la empresa. En su viaje de regreso, el sistema de vehículo también entrega palés vacíos a los paletizadores.
Además de una eficiencia optimizada y una mayor eficacia global de los equipos, esta solución permite una gestión mucho mejor del personal. El equipo de trabajo en la planta de Cikedokan ahora tiene una línea de producción más organizada y eficiente, que puede funcionar de manera continua y utiliza el espacio de forma más inteligente.
Resultados que superan las expectativas
«A pocas semanas de la instalación, realizamos un ensayo cuyo resultado demostró que la maquinaria superaba considerablemente los estándares de aceptación que habíamos establecido al inicio del proyecto. Desde entonces, no hemos observado absolutamente ninguna reducción en la eficiencia del funcionamiento de los equipos en comparación con el día de ese ensayo», abundó McClean.
En definitiva, desde la implementación de la solución, la planta ha aumentado su eficiencia en 50% y cuenta con una mayor eficacia global de los equipos.
«Uno de los deseos de Coca-Cola Bottling para todas nuestras plantas en Indonesia es seguir una estrategia de fabricación Lean. Nuestra planta de Cikedokan es como un sitio piloto: allí probamos y perfeccionamos nuestras ideas de producción LEAN, antes de implementarlas en otras plantas. De esta manera, la solución de fin de línea de Gebo Cermex que seleccionamos debía adaptarse a nuestra estrategia de fabricación Lean».
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Los tres paletizadores suministrados por Gebo Cermex tienen forma de U: la alimentación de los palés vacíos y la salida de los palés llenos se encuentran del mismo lado de la máquina. El sistema de vehículo transporta continuamente los palés cargados a un transportador, donde se los enfaja antes de llevarlos a los elevadores de horquillas que los esperan. Luego, se los traslada para su despacho a los depósitos de la empresa. En su viaje de regreso, el sistema de vehículo también entrega palés vacíos a los paletizadores.