Glico’s Smart Manufacturing and Digital Transformation Journey with Mendix
Manufacturers are increasingly adopting smart digital solutions to optimize processes on the factory floor and throughout their supply chains.
Ezaki Glico Co., Ltd. (Glico) is a leading Japanese confectionery manufacturer that operates 13 domestic and 3 overseas factories, and employs over 5,000 people. As the company expands its global operations, it is focused on improving production efficiency by building smart manufacturing factories.
To support this transformation, Glico introduced the Mendix development platform in 2022 to support continuous innovation and agility. They have since driven in-house development with low-code, improved business efficiency, and optimized facility maintenance.
Bridging the Software Delivery Gap
Glico production factories traditionally took a “buy rather than build” approach, primarily purchasing commercial off-the-shelf (COTS) solutions to address their business processes and occasionally addressed bespoke projects using Microsoft Power Apps or Java.
The reliance on COTS systems and a lack of standardization resulted in:
- A lack of flexibility and standardization leading to data siloes
- Operational inefficiency due to the increased use of outdated processes such as Excel, whiteboards, paper, and Microsoft Teams
- Disconnected and underutilized data with no centralized system and inability to share knowledge between factories and departments
Due to the nature of their business and the impact of shifting regulations and requirements, Glico needed software that was more flexible, efficient, and sustainable.
“The complexity of our on-site work processes made it practically impossible to achieve complete standardization,” explained Hajime Suzuki, R&D Group Manager at Glico.
In its search for a more adaptable solution, Glico found Mendix, which met several key criteria:
- Compatibility with other technologies such as AWS, IoT, and generative AI
- User-friendly development features
- Prototyping capabilities for testing and planning
- Flexibility to meet diverse business needs
- Industry reputation as a Siemens organization
Mendix offered Glico the opportunity to connect its factory data seamlessly and securely.
In parallel, Glico embraced Agile development to foster better and more frequent collaboration across teams. Business users became more involved in the software development lifecycle – from discovery through task setting – resulting in faster outcomes and more tailored solutions.
With their new software platform and Agile strategy in place, Glico began tackling longstanding challenges and driving improvements with low-code.
Transforming Facility Maintenance
In food manufacturing, stable operation equipment is essential to deliver high-quality products to customers. With a growing labor shortage, the need to automate and transform equipment maintenance became paramount.
For years, the high cost and rigidity of packaged software prevented Glico from building an effective facilities maintenance management tool. Mendix made it possible to tackle long-standing challenges like reliance on specialized personnel, siloed equipment data, and a lack of data-driven operations.
The development of Facility Maintenance Management System kicked off in June 2022, with the first iteration going live just seven months later in January 2023.
The application packs several essential features:
- A comprehensive equipment asset ledger tracking maintenance, work, failure, and part replacement history.
- Planned maintenance, from scheduling to workflow management.
- Inventory management that pulls data from warehousing and shipments.
- In-depth analysis and KPI management for metrics like mean time between failures, inventory turnover, and work progress rates.
“In addition to making information more accessible, automating data analysis streamlined task management, saving us an impressive 991 hours annually,” Suzuki shared.
Suzuki emphasized that the goal is not merely to improve operational efficiency, but to leverage data to optimize the entire business process in a sustainable way that secures long-term market competitiveness.
This includes reducing waste through smarter inventory management, minimizing unplanned downtime with preventive measures, and achieving stable operations through optimal maintenance practices, all of which contribute to enhanced quality, cost efficiency, and supply stability.
The Facility Maintenance Management System was well-received by users, and Glico plans to roll it out across all its factories, both in Japan and internationally. Moving forward, they will build on the success of this first application, diving into predictive maintenance and leveraging AI to push the boundaries of what’s possible in production.
Powering Smart Manufacturing with AI
In the world of smart manufacturing, artificial intelligence is everywhere, offering limitless potential. Glico made a strategic choice to adopt Mendix as it can seamlessly integrate with emerging technologies, ensuring they stay ahead of the curve.
“With Mendix, we can easily scale our development to incorporate cutting-edge technologies like generative AI, allowing us to tackle bigger challenges while focusing on continuous innovation,” Suzuki explained.
Looking to the future, Glico plans to deepen AI integration in their production processes, with initiatives such as AI-powered visual inspections and optimized automatic inventory management.
From Production Line to Enterprise-wide Innovation
Glico is setting the bar for how low-code can transform the shop floor, driving both digital transformation and process automation at a rapid pace.
By pairing low-code with their existing Java development, Glico can create powerful applications quickly without disrupting their current systems. When evaluating project fit for future development, Glico plans to use the following:
- Mendix for medium to large, complex software projects, particularly those that require integration with IoT, AI, or AWS.
- PowerApps for small, single-function solutions that integrate with Microsoft 365.
To further enhance their employee experience through smarter operations, Suzuki sees Mendix as the key to unlocking even more potential.
“Factories often have individually optimized processes and systems, and while ‘fit to standard’ is the ideal, it’s challenging. We believe Mendix can serve as the bridge to make this happen,” he explained.
The team plans to integrate Mendix with their MES, ERP, and logistics systems, all while fostering greater collaboration within their teams.