Tyson Foods
Tyson Foods improves its production yield with AVEVA PI System
Tyson Foods' Jimmy Dean sausage plant processes more than 150 million pounds of sausage every year. A lack of visibility into production operations led to avoidable waste, and undetected defects on the line caused costly delays that weighed on the site's profitability. The manufacturer automated its processes with Rockwell Automation's FactoryTalk Historian, powered by AVEVA PI System. Teams now have real-time access to weight per line, availability rate and the number of saleable products (chubs) generated in each cycle. The benefits match the stakes: an overall yield improvement of 0.1% that paid for the project in just six months, a 50% reduction in waste and giveaway, and eight labor hours saved per day. Tyson now has higher-performing, more profitable production that is firmly focused on operational efficiency for its customers.
Testimonials
FAQ
How does AVEVA PI System improve yield at a food processing plant?
Tyson Foods' Jimmy Dean plant, which processes more than 150 million pounds of sausage per year, automated its processes with FactoryTalk Historian powered by AVEVA PI System. Teams now have real-time access to weight per line, availability rate and the number of sellable products (chubs) generated in each cycle. This quantified visibility delivered an overall yield improvement of 0.1%, enough to pay for the project in just six months and demonstrate the value of real-time data in high-volume food production.
How can a data platform cut food waste by 50%?
Before AVEVA, a lack of visibility into Tyson Foods' operations led to avoidable waste and undetected defects. AVEVA PI System gives operators real-time KPIs that let them act immediately on deviations. The result: a 50% reduction in waste and product giveaway, a considerable gain for a plant processing 150 million pounds a year. This performance illustrates the value of data in aligning actual output with theoretical targets in high-volume industries.
What ROI can a PI System project generate in the food industry?
At Tyson Foods, the investment in AVEVA PI System paid for itself in just six months thanks to a 0.1% yield improvement. At the scale of 150 million pounds of sausage produced annually, this small percentage gain represents millions of dollars in recovered value. Combined with a 50% reduction in waste and a saving of 8 labor hours per day, the cumulative ROI shows that food manufacturers have significant data potential, often underused for lack of a suitable platform.
How does AVEVA detect hidden defects on a production line?
Before AVEVA, undetected defects on the Jimmy Dean line caused costly delays. AVEVA PI System collects equipment signals (weight, speed, process conditions) at high resolution and flags drifts that signal an imminent defect. Operators step in before the defect spreads, avoiding large-scale scrap and line stoppages. This early detection is a major lever for industrial performance, particularly valuable for food producers running at high speed.
How does AVEVA free up time for food industry field teams?
Tyson Foods saved 8 labor hours per day thanks to AVEVA PI System by automating previously manual data collection. Operators no longer enter data into spreadsheets or paper reports, but focus on value-added work: analysis, improvement and problem-solving. This reallocation of tasks improves team engagement, speeds up decisions and supports the culture of continuous improvement that is essential in a highly competitive sector where every point of efficiency counts.