Redefining Efficiency, Empowering Teams, Elevating Outcomes
For over 30 years, Ofi has been a global leader in food and beverage ingredients, supplying high-quality cocoa, coffee, dairy, nuts, and spices to customers in over 8,000 markets worldwide. With more than 100 factories, Ofi has built a reputation for quality and innovation. However, growth has also meant increasing complexity and accompanying challenges.
One of its largest cocoa plants faced a key problem: underperformance on a critical production line. Teams were stuck in a cycle of manual data collection, with slow progress. Their initial goal was modest—improve yield by 2-3%. Yet, as they began their digital transformation journey with Braincube, Ofi unlocked something much bigger: a whole new way to approach manufacturing.
From Fragmented Efforts to Unified Insights
Previously, Ofi’s teams relied on intuition and manual calculations to troubleshoot production challenges—a process that left key sources of variability unexplored and poorly understood.
“Our team had hunches about where to look for improvements, but without high-quality data, progress was slow and limited,” recalls GK Lee, Process and Data Analytics Manager at Ofi.
Braincube’s Product Clones transformed this approach. By contextualizing sensor and system data, Braincube provided a comprehensive, end-to-end view of operations. For the first time, Ofi’s teams could analyze variables across the entire production process, connecting the dots across material flows, key parameters, and performance.
Exceeding Expectations: Breakthrough Performance
Armed with Braincube’s insights, Ofi’s engineers and operators implemented AI-recommended setpoints and optimized parameters to address bottlenecks. The results were game-changing:
- 6.5% increase in yield, exceeding their original target.
- 25% improvement in throughput, enabling faster production cycles and reduced downtime.
- Enhanced production quality, resulting in lower waste, greater savings, and enhanced customer satisfaction.
And the impact went beyond numbers. Braincube enabled a shift from reactive troubleshooting to proactive optimization. Live updates from the shop floor allowed operators to implement improvements in real time, creating a seamless feedback loop between analysis and action.
A New Vision for Manufacturing
What started as a single production line project has sparked company-wide transformation. By integrating Braincube’s Productivity Management System across operations, Ofi is scaling innovation and driving improvements across multiple sites.
Equally important, Braincube has empowered employees. Engineers fine-tune operations using real-time insights, while operators collaborate to enhance efficiency and quality.
“We’re not just solving problems—we’re setting the stage for continuous improvement,” says Lee. “Braincube has shown us that with the right tools and vision, we can achieve far more than we ever imagined.”
Building a Legacy of Innovation
Ofi’s journey highlights the transformative power of combining vision with expertise and technology. By moving from intuition to precision, they’ve turned a single challenge into an opportunity to redefine processes and inspire their teams.
“Braincube’s impact goes far beyond the technology,” Lee reflects. “It’s transforming how we work and innovate, ensuring every success propels us closer to a smarter, more resilient future.”
With plans to expand Braincube’s capabilities across other factories and business units, Ofi is pursuing new opportunities to enhance sustainability, reduce costs, and elevate performance.
Equally important, Braincube has empowered employees. Engineers fine-tune operations using real-time insights, while operators collaborate to enhance efficiency and quality.
“We’re not just solving problems—we’re setting the stage for continuous improvement,” says Lee. “Braincube has shown us that with the right tools and vision, we can achieve far more than we ever imagined.”
