201104 food manufacturing and automation show
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Transcript of 201104 food manufacturing and automation show
How do you achieve compliance, improve efficiencies and gain competitive advantage?
The Question…
what’s in a number?these numbers tell a story about
food safety
50
10
500
1
what’s in a number?these numbers tell a story about
food safety
a single food product may contain over 50 ingredients,
where many ingredients are sourced globally and have been touched by 10 or more business entities.
a single manufacturer may have over 500 unique suppliers of ingredients,
and it only takes 1 incident to destroy a company.
2006
2007
2008
2009
2010
total numberof food recalls 200
0
600
400
800
global food safety initiative (GFSI)
safe quality food (SQF)
food safety modernization act (FDA)
ISO 22000
bio-terrorism act of 2002
british retail consortium (BRC)
USDA
how can
manufacturers comply?
Quality SPC
PlantMaintenance
Fragmented Data Sources
Traceability
OEE
DocumentControl
HACCP
HR – Skills Matrix
ComplianceManagement
the status quo
instant traceability
&recall mgt
food quality&
electronic HACCP
ERP
manufacturing operations
management system (MOMS)
instant traceability
&recall mgt
food quality&
electronic HACCP
ERP
• shop floor data collection• human machine interface (HMI)• mobile device operations • OEE reporting • rejection tracking• machine integration (SCADA)• allergen control• production scheduling• pick, pack & ship
MO
MS
MO
MS
Control Panel
Control Panel
Control Panel
ProductionRecording
ProductionScheduling
BarcodeLabeling
Control Panel
ProductionRecording
ProductionScheduling
BarcodeLabeling
QualityReporting
HACCPReporting
Control PanelPlant & Quality
Bulletins
ProductionRecording
ProductionScheduling
BarcodeLabeling
QualityReporting
HACCPReporting
Control PanelPlant & Quality
Bulletins
MaintenanceWork Orders
GaugeCalibration
Control
ChecksheetHistory
ProductionRecording
ProductionScheduling
BarcodeLabeling
QualityReporting
HACCPReporting
Control PanelPlant & Quality
Bulletins
MaintenanceWork Orders
GaugeCalibration
Control
ChecksheetHistory
DocumentControlAccess
ProductionRecording
ProductionScheduling
BarcodeLabeling
QualityReporting
HACCPReporting
Control PanelPlant & Quality
Bulletins
MaintenanceWork Orders
GaugeCalibration
Control
ChecksheetHistory
DocumentControlAccess
ProductionRecording
ProductionScheduling
BarcodeLabeling
QualityReporting
HACCPReporting
Time ClockTraining
OSHA Reporting
EmployeeInnovations
PLCIntegration
MO
MS
Enabling mobility
MO
M Enabling OEE
• HR – skills matrix• visitor log• supplier approval & scorecarding
• accounting & finance • advanced product costing• CRM• maintenance management• purchasing
traceability&
recall management
manufacturing operations
management system (MOMS)
ERP
food quality &
electronic HACCP
• HR – skills matrix• visitor log• supplier approval & scorecarding
• accounting & finance • advanced product costing• CRM• maintenance management• purchasing
traceability&
recall management
manufacturing operations
management system (MOMS)
ERP
• embedded document control• compliance management• electronic HACCP • checklists / SOP’s• corrective & preventative action • critical control point alarming• SPC charting• electronic signature• workflow
food
saf
ety
eHAC
CP Enabling eHACCP
Enabling eHACCP
Enabling eHACCP
Enabling SPC
• HR – skills matrix• visitor log• supplier approval & scorecarding
• accounting & finance • advanced product costing• CRM• maintenance management• purchasing
Instant traceability
&recall mgt
ERPfood quality
&electronic
HACCP
manufacturing operations
management system (MOMS)
• HR – skills matrix• visitor log• supplier approval & scorecarding
• accounting & finance • advanced product costing• CRM• maintenance management• purchasing
traceability• graphical product genealogy• extended supply chain tracking• lot trace and trace• allergen tracking
• reduce scope of a recall• quickly contain tainted product
ERPfood quality
&electronic
HACCP
manufacturing operations
management system (MOMS)
• Bleached Enriched Wheat Flour– Wheat Flour, Niacin, Reduced Iron, Thiamine Mononitrate, Riboflavin, Folic Acid,
• Candy Pieces– Dark Chocolate - Sugar, Chocolate liquor, cocoa butter, butter oil, soy lecithin, vanillia– Sugar, Yellow #5 Lake Yellow, Yellow # 6 Lake, Blue #2 Lake, Red #40 Lake, Blue #1, Yellow
#6, Yellow #5, Blue #1, Gum Arabic, Corn Syrup– Confectioners Glaze - Carnauba wax, beeswax and shellac
• High fructose corn syrup• Butter
– Pasteurized cream, water, lactic Acid
• Sugar• Shortening
– Canola Oil, Hydrogenated cottonseed oil, citric acid
• Eggs
• Contains less than 2% of 6 other ingredients
what’s in this cookie?traceability
traceability
traceability
traceability
ERPInstant
traceability&
recall mgt
• HR – skills matrix• visitor log• supplier approval• accounting & finance• advanced product costing• CRM• maintenance management• purchasing
food quality&
electronic HACCP
manufacturing operations
management system (MOMS)
food
saf
ety
traceabilityERP
• HR – skills matrix• visitor log• supplier approval• accounting & finance• advanced product costing• CRM• maintenance management• purchasing
• embedded document control• compliance management• electronic HACCP •checklists / SOP’s• corrective & preventative action •critical control point alarm• SPC charting• electronic signature• workflow
• graphical product genealogy• extended supply chain tracking• lot trace and trace• allergen tracking
• reduce scope of a recall• quickly contain tainted product
MO
MS
• shop floor data collection• human machine interface (HMI)• mobile device operations •OEE reporting •rejection tracking• machine integration (SCADA)• allergen control• production scheduling• pick, pack & ship
Instant traceability
&recall mgt
ERPfood quality
&electronic
HACCP
manufacturing operations
management system (MOMS)
enterprise food safety
management & ERP
Research
Maps
Business Software
“The Cloud”
ITEM On Premise PLEXSoftware Up-front; expensive;
Database, Application, Middleware, Server OS; CALS
Included
Hardware Up-front and expensive; Servers; backups; disaster recovery; cooling systems; test and production system
Included
Customization Customer managed; inhibits upgrades; costly. Becomes Standard
Versions and Upgrades
12-18 month release cycles. Must stay current to get support. Upgrades difficult and costly
Always on the latest version w/ Opt-in enhancements
Productivity Lower – can’t access system remotely Higher – Workers access system anytime, anywhere
TCO Higher – IT Operation (security DBA, report writing, developers, etc.), Support costs
Lower –Optimize IT Operations; more efficient support
Flexibility Tougher to adapt business system to changing business climate
Easy to adapt to changing business climate
Benefits of Cloud
twitter:
blog: foodsafteymanagement.wordpress.com
Jon Cowan – [email protected] Nessen – [email protected]