Consumer Packaged Goods (CPG) manufacturers operate in a fast-paced environment defined by fluctuating demand, tight margins, and constant pressure to deliver on time. Whether producing snacks, personal care items, or cleaning products, CPG manufacturers must make the most of every resource—people, machines, and materials. But increasing capacity doesn’t always mean investing in new lines or equipment. Often, it’s about unlocking the potential of what you already have. That’s where smart factory software like Nulogy Smart Factory (formerly Mingo) makes a difference.
How CPG Manufacturers Calculate Capacity
At its core, capacity in CPG manufacturing is determined by how many units a line or plant can produce over a defined period, based on factors such as cycle time, shift patterns, changeover time, and equipment availability. The challenge, however, is that theoretical capacity rarely matches actual output due to frequent stoppages, delays, and inefficiencies.
With Nulogy Smart Factory, manufacturers can monitor real-time production data, giving them an accurate picture of how each line is performing. This data includes machine speeds, actual versus target cycle times, and downtime causes—helping teams calculate true available capacity instead of relying on assumptions or outdated estimates.
Common Causes for Constrained Capacity
For CPG manufacturers, capacity is often constrained not by equipment limits but by avoidable inefficiencies. Common issues include:
- Unplanned Downtime: Whether caused by equipment failure, material shortages, or operator issues, unplanned stoppages reduce available production time.
- Manual Reporting: Paper-based systems or spreadsheets delay visibility into what’s happening on the floor, making it harder to respond to problems in real time.
- Inaccurate Data: Without accurate cycle times or output data, teams can’t properly schedule production or identify bottlenecks.
- Complex Changeovers: Frequent product changeovers can eat into valuable production time if not managed efficiently.
These issues often go unnoticed or unresolved when manufacturers don’t have access to real-time, granular production data.
The Value of Real-Time Visibility
Smart factory software solves this problem by delivering real-time visibility into plant performance. Nulogy Smart Factory collects data from machines, sensors, and operators to provide instant insight into productivity, downtime, and quality.
Operators and supervisors can see live production stats on dashboards or scoreboards, helping them react quickly to issues and maintain steady flow. Plant managers and CI teams can identify trends over time—whether a filler is running faster than the capper or if a packaging line consistently underperforms.
Nulogy also integrates with ERP and CMMS systems, linking production monitoring with maintenance and planning workflows. This unified data allows teams to make decisions based on facts, not guesswork.
Real-World Results from Mingo Customers
CPG manufacturers using Nulogy Smart Factory have reported significant gains:
- Downtime reduced by as much as 70%
- Manual reporting time cut by 8 hours per week
- Improved ability to detect cycle time discrepancies (up to 20%)
- Faster response to bottlenecks and line issues
For example, Louisiana Fish Fry—a food manufacturer—leveraged Nulogy to uncover the root causes of downtime and increase throughput without adding new lines. Real-time data enabled their team to proactively manage maintenance and optimize staffing based on actual production conditions.
Increasing Capacity Without Adding Cost
In today’s market, increasing output doesn’t have to mean hiring more staff or buying new equipment. By using Nulogy Smart Factory to get real-time visibility into operations, CPG manufacturers can eliminate waste, improve line balance, and confidently take on more volume.
If your team is struggling to hit targets or make data-driven decisions, it may be time to modernize your factory floor with smart factory software. Explore the full capabilities of Nulogy and see how real-time production monitoring can help unlock the capacity you didn’t know you had. Request a demo or talk to an expert today.
