Case Study: Clif Bar achieves 75% self-manufacturing and standardized operations with AVEVA Wonderware MES & Historian

When the popular energy and snack bar manufacturer began self-manufacturing in 2014, it turned to AVEVA’s MES system to support its strategic initiatives

Clif Bar, the energy and snack bar manufacturer, faced a major shift in 2014 when it decided to move into self‑manufacturing for the first time. The company needed to launch a greenfield plant in Twin Falls, quickly adopt the same operating architecture in a newly acquired brownfield plant in Indianapolis, integrate with ERP and varied OEM hardware, and build a data‑driven culture to support its Five Aspirations. To meet these challenges, Clif Bar selected AVEVA’s Wonderware MES and Historian as the core systems for operations and analytics.

AVEVA implemented Wonderware MES and Historian (with system integrator support) to standardize processes across greenfield and brownfield sites, integrate with ERP and legacy equipment, and deliver real‑time and historical analytics for OEE, energy monitoring, quality, and traceability. The solution enabled Clif Bar to go from manufacturing 0 to about 75% of its own bars within one year, succeed in concurrent greenfield/brownfield launches despite a compounded <8% chance of success, and build a continuous‑improvement foundation—including two years of Historian data that now supports predictive analytics, better capacity planning, and improved quality control.

Clif Bar

Dale Ducommun

General Manager