Moving From Art To Science

Moving From Art to Science

Manufacturing in the 21st Century

Your Workforce

Past Present

Employee Life Less than 3 years

Progression Decade Months

Living for Future Now

Work life balance Work Life

Process Art Control/data

Process knowledge High Low

Work Load Reasonable Overburdened

Job Function Well Defined Multiple Roles

Computer knowledge Low High

Moving From Art to Science

Cost + Control

Resource Cost Control

Materials $$$ Yes

People $$$ ?

Assets $$$$$$$ Yes

Parts $$ Yes

Process ? ?

Improving Cost Control & Throughput with Process Control

Your process combines the costs of materials, people, assets, and parts for all activities needed to make each product. When you control each area, you can control your costs.

Increase Throughput

• Raw material receiving / storage• Processing/batching• Pasteurized/processed product

storage• Filling / Packaging• Effluent• CIP

Do you have the visibility of these areas of the process?

If you could improve flow through one area would it improve performance and profitability?


Process Control

• What should you control?– Variables

• Why do you need to control them?– Repeatability – Consistency

• How are you going to control them?


Managing Operations with Information

Receiving► Problem: Only visibility to receiving operations is paper trail• Original hardware & software controls to move

milk, actuating pumps, valves, air-blows

► Solution: Added additional hardware & software• Meters and software to integrate compositional data, truck, transport

data, testing data, billed and scaled amounts, destination tanks, flows and tank levels

► Results: Caught losses of milk left on tanker (20 gal to 1000 gallons)

• Immediate HMI view and notification on large losses• Used information to study trends by operator, driver, carrier, day of the

week, receiving bay, etc.• Discovered loss occurring late on weekends with one driver• Broke multi-million dollar theft ring

Real Life Dairy Manufacturing Problems and Solutions

Cream Press

►Problem: “Blew Cream Press”• Lost material, lost time, inconsistent fat level

►Solution: New plate package and Automated controls

►Results: Consistent BF, improved temperature control, improved yield

• Improved visibility of the process


Managing Inventories• Collection tools: Paper and

pencil or sensor technology• Automation: Track amount,

usage and temperatures• View in plant at HMI and on

desktop• Provide alerts and information

for plant operations, purchasing, sales, planning, and other departments

• Provide emailed or live inventory to suppliers to assist in managing inventory levels to match usage


Contaminated Product

• Discovery: Visually on display (Tank temperature too high, volume too high)

• Correlation: Events – Receiving and CIP• Identification: Sequence of events and operators responsible• Control: Liability

ChemicalsMilk


Batch

Typical ProblemsVariables to Measure &

Control

Missing Ingredients • Flows

• Quantities

• Ingredients

• Agitation

• Mixing

• Temperature

Wrong Ingredients

Wrong BF

Under-Stabilized

Over-Stabilized

Over-Fortification

Wrong pH

Wrong BRIX

Air Incorporation


Pasteurizing Process – Under Utilized

Idle


Forward Flow

CIP

Pasteurizing Process – Time Lost

Recycle

Divert

Forward Flow


CIP

Filling / Packaging

Quality, Yield, Utilization Issues

Measurements Area Affected

Leakage Visual/Electronic Shrinkage

Over/under fill Scale/Volumetric Shrinkage/Lost Sale

Volume Metered in vs. Package Count

Meter value, Sensor Yield and Shrinkage

Lack of packaging Bottles, packages per minute OEE

CIP/COP Duration of CIP Availability

Downtime too highNumber/duration per shift per reason

OEE, Distribution

Changeovers Number/duration per shift Throughput

Wrong product Product, tank, label, time Shrinkage, OEE


Cost Control and Process Control

►“Get what you pay for”

►Control inventory• Monitor Receipts vs. Billing vs. Shipments

►Effective use of resources and assets• Waste or Loss Reduction

• Resource in equals Finished Product out

►Efficiently use of resources and assets• Manpower reductions

• Increase machine time available for sales

►Develop accurate costing• Activity Based Costing

Sustain Results ►Train and Empower People• Job knowledge to make good decisions• Authority to make decisions

►Provide Effective Tools and Systems

►Provide Accurate, Actionable Information• Information is real-time, with correlated events

►Act on the Information• Given the responsibility and training to act • Held accountable for actions

►Achieve Sustained Results• Ownership and Reward

Shrink Control/Loss Prevention

ABC Dairy► Problem:

• Monthly loss of butterfat (3%), total loss (2.5%)• Needed visibility because only knew loss on monthly basis

► Solution:• Hardware/software installed to measure product

metered into and out of each area of the plant.• Developed daily utilization reports based on predicted or

expected yield vs. actual and identify loss by area.• Reduced loss in receiving, storage, batching, processing, and

packaging to less than 1%.

► Results:• Annual savings: $600,000

Controlling Costs and Sustaining Results

Effluent/Waste WaterXYZ Dairy►Problem: Fines for Fats, oils and grease in waste stream

►Discovery: • Test for fats, oils, greases• Butterfat was the largest contributor

►Solution:• Hardware/software; installed optical sensor, opacity meter,

recording system, annunciator

• When sensor alarmed, immediately responded to all plant areas

• Isolated areas and found sources (CIP, Separator, Cream Loadout)

• Developed new procedures and added programming to reduce loss of product and eliminate violations

►Results: • Annual savings: $80,000

Controlling Costs and Sustaining Results

Rudy’s Top 5 Focus Areas

Contact Information

Rudy WesterveltPresident

[email protected](909) 563-8700

mailto:[email protected]

Moving From Art To Science

Technology

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