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- OEM
Gaining Productivity & Efficiency in Wine Manufacturing
75% Efficiency Gain Achieved with AE’s Precision Change Parts
Downtime loss avoided: $5,000–$20,000/hr
+75% efficiency improvement on one line
+30% productivity gain on a second line
Seamless Lean & Green implementation at scale
The Challenge
Alternative Engineering:
Long OEM lead times for replacement parts
Bottling line issues during packaging upgrades
Production delays caused by ill-fitting components
Costly downtime, with potential losses of up to $20,000/hour
TWE also aimed to introduce new Lean & Green bottling tech without compromising quality or output.
The Solution
Alternative Engineering:
Reverse-engineered and locally manufactured precision change parts
Digitally measured tolerances to 3 decimal places for a perfect fit
Delivered rapid turnaround under tight project timelines
TWE also aimed to introduce new Lean & Green bottling tech without compromising quality or output.
Outcome
| Metric | Result |
|---|---|
| Line Efficiency | +75% (from 65% to 90%) at Casella |
| Productivity Gain | +30% on a second Casella line |
| Output Increase | +10% improvement at Treasury Wine Estates |
| Downtime Avoidance | Significant savings: $5k–$20k/hr risk mitigated |
| Part Accuracy | First-fit success with zero rework |
“Alternative Engineering produced accurate change parts that fit our machines perfectly.
Anthony Zuccato
Maintenance Supervisor, Casella Wines
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