Perishability and Shelf Life
Managing the natural degradation of ingredients to ensure the quality of the delivered product
Challenge
Products shelf life must be considered to optimize supply chain because first it is a major constraint and second otherwise the plan is not accurate
Need
- Optimize lot allocation to respect customer requested shelf life
- Fulfill customer requirement in quantity and requested shelf life
- Minimize production waste
- Alert on lot expiration criticality
- Optimize lot allocation to account for perishability
Solution
- Model product shelf life and consider it during optimization and pegging
- Integrate stock orders and their shelf life
- Alert on expired work orders and stock orders.
- Link stock orders to work orders.
- Visualize in material chart the expired quantity per period.
- Visualize lot criticality (color + global KPI).
Allergen Management
Reducing cross-contamination to meet allergen regulations and make safe products
Challenge
Regulation and quality in food and beverage industry continue to become more complex. Customer requirements in terms of allergen product is one perfect example of complexity for the industrials. This complexity must be consider during the scheduling phase to secure regulation respect.
Need
- Guarantee the regulation respect and quality.
- Improve productivity by reducing cleaning between allergen products.
Solution
- Define markers to highlight product with a lot of allergens.
- Define specific color per group of products according to theirs allergens.
- Define multiple changeover times an continuous changeover time to specify sequence rules in production.
- Define possible connections between machines.
- Optimize the schedule regarding allergens
Production campaigns
Delivering campaign strategy efficiently and effectively
Challenge
Campaign is a key element in Food & Beverage scheduling in order to minimize setup time and facilitate daily operations.
Typically, production and packaging have different mindset concerning the campaign management
Need
- Improve productivity by reducing cycle cleaning
- Gain efficiency by automating cleaning times
- Monitor progress with appropriate indicators
Solution
- Automatically calculate changeover times according to rules.
- Optimize the schedule regarding changeover time.
- Define multiple changeover times per operations.
- Have a clear vision of campaigns with color in planning.
- Have the possibility to define continuous parameter (from smaller value to bigger one or the opposite).
- Define several optimization criteria to find the best compromise between service rate and campaigns.
Raw Material Inventory
Matching the raw material needs and ordering process to the planned production
Challenge
Raw materials in food & beverage industry can be challenging due to variety, shelf life, procurement constraints, seasonality and cost.
They must be considered to propose a feasible plan and anticipate the need to order more ingredients
Need
- Create feasible plans that align with raw materials (available and ordered)
- Reduce the operational cost of maintaining excess raw material inventory
- Minimize waste through spoilage of spoiled raw materials and unfinished goods
- Avoid delays to customer deliveries caused by delayed production
Solution
- Visualize shortage per raw material and order them by shortage
- Display detailed information per material (planned on hand, stock cover, requirement…).
- Highlight work orders impacted by shortage
Traceability
Tracking the journey of food products through every stage of the supply chain
Challenge
Regulation and quality in Food & Beverage industry continues to become more complex.
Traceability must be considered during the scheduling phase to meet regulation and ensure high quality products.
Need
- Comply with regulatory rules thank to material traceability using specifics pegging rules.
- Ensure traceability of lot in case of quality issue on a lot.
Solution
- Trace work orders allocation.
- Display the supply of each work orders including stock orders.
- Generate pegging between existing work orders respecting authorized supply types.
- Generate semi-finished work orders and their pegging to finished work orders respecting authorized supply types.
- Archive pegging between work orders thank to reporting tool.
- Keep in memory the pegging between work orders.
- Have several product versions with availability dates.
Complex process synchronization
Synchronizing work in process operations to deliver the final product on time
Challenge
Process are often complex due to challenging synchronization between operations. Moreover, it is not unusual to find in Food & Beverage industry tank with drain constraint or machine with capacity constraint. Respect those specific problematic is required to deliver a feasible plan.
Need
- Gain in visibility across the full process.
- Have a feasible and accurate plan.
- Reduce lead time considering production constraint.
Solution
- Various types of link between operations and work orders (min or max lead time, overlap, maximum waiting time, strict synchronization…).
- Allocate specific capacity to a resource and optimize considering it.
- Connection matrix between several resources.
- Highlight critical path.
- Have KPI and visual alert to monitor the maximum waiting
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Delmia Ortems Food & Beverage rešenje