Reconfiguring a factory used to mean shutting it down, making costly bets, and hoping the design worked in the real world. PepsiCo found a way around that. Rather than rely on engineering blueprints to solve the problem, the company used a specialized laser to scan the facility and create a digital representation that was accurate to within a millimeter. It then used this 3D model to simulate the current manufacturing process and identify production bottlenecks. This exercise gave engineers a blank canvas to experiment with new layouts that would help expand and speed up production—all before touching a single machine.
“What you’re trying to do is optimize every part of the space, from the hardware and the software to how people navigate through the space,” says Athina Kanioura, PepsiCo’s CEO, Latin America, and global chief strategy and transformation officer. “We’re taking every data point within the design of the physical infrastructure to create millions and millions of simulations to design the perfect building.” In recent years, artificial intelligence
