Doubling production by 2030: Granado brings Cogtive to its Japeri plant

The challenge

Cosmetics manufacturer Granado has set itself a clear goal: double its production by 2030. The starting point is its manufacturing plant in Japeri, in the Baixada Fluminense region of Rio de Janeiro, where management is already automated and growth has been steady.

“Since it opened in 2014, the plant has shown impressive growth, with volume increasing by more than 10% a year and around 1,000 employees working four shifts across our manufacturing complex,” says Rodrigo Monteiro, Granado’s industrial director, who leads the project.

Doubling output from that base takes more than adding volume. It means finding where time is lost on each piece of equipment and between production stages, and acting on it shift after shift. The product environment raises the bar. “It’s an extremely relevant strategy, since the cosmetics segment presents a dynamic and challenging manufacturing environment, with constant new product launches and complex packaging,” says Reginaldo Ribeiro, CEO of Cogtive.

Frequent launches and complex packaging put pressure on equipment performance and on the flow of each batch through the plant. To keep growing at that pace, Granado needed precise, real-time indicators on both.

The solution

Granado invested in Cogtive to drive productivity gains at the Japeri plant. As Monteiro explains, Cogtive can identify bottlenecks and reduce the time needed to complete production of a batch, while providing precise indicators on equipment performance and a clear view of the production flow.

Two layers of the Cogtive cockpit deliver that:

• OEE foundation. Real-time equipment indicators show how each machine is performing: OEE, FIFO, the downtime Pareto, the current event, speed, the equipment timeline and setup. Losses are recorded as they happen, so the teams can see which stops cost the most and where to act first.
• Flow View. The production flow is virtualized in what began as Cogtive’s digital productivity kanban, now Flow View. Every process is tracked with real-time information on each stage and each piece of equipment, which shows where batches wait between stages and where the time to complete a batch builds up.

The OEE foundation shows how each machine performs. Flow View shows what happens between machines. A plant growing more than 10% a year needs to see both to know which constraint to remove next.

The expected results

Granado expects the project to raise productivity and speed up decision-making at every stage of the shop floor, from production managers to the maintenance and setup teams. Real-time indicators put the same facts in front of each of those teams.

Ribeiro also highlights the project’s potential to support Granado’s sustainability goals: cutting costs and environmental impact, generating less waste and reducing energy consumption.

The target is set: double production by 2030 at a plant that has grown more than 10% a year since 2014. The foundation for reaching it is a shop floor where performance and flow are measured in real time.