How PepsiCo Built AI-ready Data for Manufacturing Intelligence
60% Batch Deviation Addressed | 6% Efficiency Improvement
PepsiCo’s Patiala plant had a measurable problem: steam utilization in potato chip production was running at 1.08-1.12 KG/KG against a target of 1.02 KG/KG. That gap meant higher fuel costs, increased operational spend, and difficulty meeting sustainability targets. But the root cause wasn’t visible. Sensor data, SCADA logs, and operational records sat in separate systems. 60% of batches were deviating from target, and the plant had no way to connect operational patterns to efficiency outcomes.
ADA delivered a phased implementation. Phase 1 built plant monitoring dashboards with alerts, giving operators visibility into equipment performance. Phase 2 explored Generative AI applications based on available data. Phase 3 deployed AI/ML models for predictive and prescriptive insights. The approach built AI-ready data foundations first, then layered intelligence on top.
