RFID enabled track & trace of Dairy Products - fhi.nl · in China Acquisition of mozzarella...
Transcript of RFID enabled track & trace of Dairy Products - fhi.nl · in China Acquisition of mozzarella...
© 2017 FrieslandCampina
RFID enabled track & trace of Dairy Products Vincent Koeckhoven, FrieslandCampina
Sander Merkx, Mieloo & Alexander
Safety
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Put your bags against the wall and out of the
way. Do not block emergency exits
When the fire alarm goes off:
evacuate the building and go to an
assembly point
In case of emergency, call this number: [please fill in
the emergency number]
Assembly point: [please fill in the assembly point]
Locate the emergency exits
Please silence your cell phone
Our Message
Inform you about Royal Friesland Campina, the OT Program and the Summit program
Give background on RFID project
Point on the key questions that arises
Deal with the challenges and current status
Q&A
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FrieslandCampina at a glance
Figures 2016 4
11.0 billion Euros revenue
100 Export to over
countries
33 Facilities in
countries employees
21,927 member dairy
farmers
18,906
millions of consumers
Every day
Founding of Arnhemse Melk-inrichting
Founding of CCF in Leeuwarden
Friesche Vlag, Dutch Baby and Bonnet Rouge are registered for international markets
Founding of Coberco in Zutphen
Merger of Coberco, Friesland Dairy Foods, De Zuid- Oost-Hoek and Twee Provinciën
Acquisition of Nutricia Dairy & Drinks Group
Friesland Foods receives Royal designation on its 125th anniversary
Founding of the first dairy co-operatives
Founding of the De Meijerij Veghel / De Melkindustrie Veghel
Campina brand introduced
Founding of Campina Melkunie
Acquisition of Südmilch (Heilbronn)
International launch of formation of international Campina brand and co-operative
Acquisition of Alaska Milk
Corporation in the Philippines
Acquisition of Zijerveld and
Veldhuyzen and
G. den Hollander Holding
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Acquisition of Olam Ivory Coast and DEK in Italy
Nine farmers take over a cheese factory in the Dutch Wieringerwaard
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Founding of joint venture
Friesland Huishan Dairy
in China
Acquisition of mozzarella
producer Fabrelac in
Belgium
Acquisition of the activities
of Anika Group in Russia
Acquisition of IDB Belgium
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Acquisition of
majority stake (51%) Engro Foods
in Pakistan
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Merger of Friesland Foods and Campina
We have a long history…
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Strategy route2020: sustainable growth and value creation
Better nutrition, a good living for our farmers, now and for generations to come
Leverage the Dutch dairy heritage and unique milk chain in a sustainable way to win the hearts and minds of our customers and consumers
Expand the leading positions in growth areas
Protect the volumes in home markets
Build future markets
Improving capabilities that are key for market success
Reducing costs to enable investments in growth
Think and act in accordance with the AAA concept
Applying the principles of good business conduct
20 Be financially healthy and in harmony with nature and society in the short term and in 20+ years’ time
15 Grow to 15 billion euros revenue in 2020
Valorise >10 billion kilos of milk from the member dairy farmers
10 5 Achieve 5% annual volume growth in the selected priority product- market combinations
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FrieslandCampina brands
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1. Friso
2. Frisian Flag
3. Dutch Lady
4. Peak
5. Alaska
6. Campina
7. Rainbow
8. Foremost
9. Debic
10. Frico
1. DMV Excellion
(caseinate)
2. Kievit Vana Blanca
(creamers)
3. Domo Vivinal GOS
(galacto-oligosacharide)
4. DFE Pharmatose
(pharmaceutical lactose)
5. Kievit Vana Grasa
(fat powders)
Top 10 consumer brands in revenue in euros
Top 5 industrial products in revenue in euros
Consumer Foodservice Ingredients
Organised in four new business groups
Consumer Dairy Specialised Nutrition Dairy Essentials Ingredients
Executive board
Corporate & Support
Business partner-driven
Development and sales of non-
branded basic products such as
cheese, butter and milk powder,
for the food industry
Responsible for optimising the
processing of milk
Business partner-driven
Close cooperation with customers
Infant nutrition, and the food and
pharmaceutical industries
Consumer-driven
Strong dairy portfolio of regionally
relevant branded products
Condensed milk, yoghurt, quark,
dairy-based beverages and
cheese
Consumer-driven
Infant nutrition and special dairy-
based food products and
supplements
Elderly people, athletes and
people with special nutritional
needs
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Maintenance of scattered landscapes = complex
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Maintenance
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Ma
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Maintenance
Definitions
Maintenance
Capability
Maintenance
Response
Maintenance
dispatchingMaintenance
analysis
Maintenance
data collection
Maintenance
tracking
Maintenance
definition
management
Maintenance
resource
management
Maintenance
execution
management
Detailed
Maintenance
scheduling
Op
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Equ
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Production
Schedule
Op
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Product
Definition
Production
Capability
Production
Performance
Production
dispatching
Production
performance
analysis
Production data
collection
Production
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Product definition
management
Production
resource
management
Production
execution
Detailed
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scheduling
Test re
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Test c
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Quality
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Quality test
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Quality test
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Quality test
dispatchingQuality
analysis
Quality test
data collection
Quality test
tracking
Quality definition
management
Quality test
resource
management
Quality test
execution
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Detailed quality
test scheduling
Invento
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Inve
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Inve
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Inventory
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Inventory
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Inventory
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Inventory data
collection
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Inventory
definition
management
Inventory
resource
management
Inventory
execution
management
Detailed
inventory
scheduling
Maintenance Production Quality Inventory
E P
I M
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Schichtplaner
EXCEL
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EXCEL PDF
OMP
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PRISM
Access
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Access
Receptur db
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FAP Excel
Quickscheduler
Drilog
EXCEL
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Access
PLMS
Patch EXCEL
GPS
(PRISM)
Satorius
EXCEL
SAP Schichtplaner ISO
EXCEL
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Access
Reklamation
EXCEL
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Access
Reklamation Drilog
Excel
QDS ISO
PC PC PC
Drilog SAP
Consulink QDS
DL DL DL
EHS satorius
EXCEL
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Aquamoni
Access
Maintenance Production Quality Inventory
DCS, SCADA, PLC
ERP
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OT program priorities
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A) OT Cyber security C) OT Governance B) OT Business Continuity
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Why SUMMIT?
is the global, multiyear programme of FrieslandCampina to implement a new operating
model to standardise and to harmonise processes, data and systems.
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The SUMMIT Program
Key objectives:
Will replace our seventeen local systems and working methods with one standard system and working method…
It will enable us to speak the same ‘language’!
Harmonization and standardization across the sites.
Real-time information and data tracking.
Coupling of factory IT/MES with SAP ECC on the GSS template
Track & trace at shipment level via GS1 SSCC (Serial Shipping Container Code)
Reduction of operational cost and headcount.
Global SAP roll-out:
Summit T10 involves 4 CPEMEA production locations (Bornem, Aalter, Maasdam, Rotterdam).
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Plant Rotterdam – At a glance
Volume Around 200 mioL for Consumer products and 100 mioL for B2B
# Filling lines 12: 0.5L / 1L /1.5 L
- Primary packaging Gabble Top
- Secundary packaging Carton and RIC
# SKU’s Over 100
# Recipes Around 25
# Batches Over 250 a week
# FTE Around 100
- Distribution Around 200 truck loads / week
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The Issue
Palletized product: ~70%
Dairy products in cartons are palletized by robots
SSCC labels are automatically attached with applicator after palletisation
Product on RIC: ~30%
Around 30.000 Roll in Containers (RIC’s) are in use by Friesland Campina and Farm Dairy
Cold, wet, not sufficient space, and no “line of sight” for labels
Automatic label application not possible 17
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Initial solution options
Manual barcode label application:
SSCC label between the cartons or a
“luggage” label
Disadvantages:
Cost: at least 1 fte per shift!
Potential to apply label to the wrong RIC.
Not compliant with route 2020 (cost reduction)
Utilize RFID technology:
Program SSCC into an RFID tag on RIC when
the RIC is being loaded:
Benefits:
Cost: no extra fte cost, per shift.
No user errors.
Additional: opportunities for improved RTI management
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Key questions
1. Can RFID tags be programmed with an SSCC and re-programmed again (and again)?
2. Which RFID tag and where to place it on the RIC?
3. How to integrate RFID technology in the new processes and systems in Rotterdam?
4. Can other benefits be realized, e.g. Supply Chain efficiency or Returnable Transport
Item (RTI) management?
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Q1: Can tags be re-programmed?
Sure!
But RIC’s are Returnable Assets and according to GS1 standards, should be
programmed with a GRAI code (Global Returnable Asset Identifier)!
Solution:
Associate the GRAI code with the SSCC each time a new batch is loaded in the RIC.
Scan the GRAI RFID tag, and get the SSCC from SAP!
New Issue:
The Summit template doesn’t support RFID scanning yet.
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RFID Tag coding and Scanning solution
Encode the GRAI in the EPC and the
SSCC in the user memory! (Global Returnable Asset Identifier)!
Use the EPC and the user
memory of the RFID tag
Extend SAP terminals with RFID device with
embedded Linux server:
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RFID device runs app to read user memory,
translate hexadecimal code to SSCC and to
support pairing with SUMMIT handheld and FLT
terminals
Q2: Which RFID tag and where to apply? (1)
Requirements:
Robust mount on metal tag with user programmable memory that can be read up to 4
meters…
Easily damaged by (internal) transport
Moving parts limit options
Liquids absorb RF energy
Best option: top of RIC
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Q2: Which RFID tag and where to apply? (2)
Requirements:
New issue: no standard on metal RFID tag available that meets all requirements!
Withstand severe mechanical impact
Limited height: < 5mm
No overhang: < 10 mm wide
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Solution: custom developed RFID tag
Solution:
Develop a custom UHF RFID tag for all 30.000 RIC’s
Test and validate against all requirements
Apply pre-coded (GRAI) tags to all RIC’s of Friesland Campina
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Omni-ID Pre-production sample
Q3: How to integrate RFID technology?
1. RFID readers at empty receiving area check
returned quantity.
2. RFID reader at conveyor infeed alerts operator
if RIC does not have working RFID tag.
3. RFID readers in RIC loading stations encode
SSCC in RFID tag.
4. RFID “curtain” above transition point to
finished product inventory – post goods receipt
in SAP via Wonderware MES.
5. RFID scanners BT connected to SAP terminal
link SSCC to outbound delivery note in SAP.
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Solution: RFID readers in RIC loaders program SSCC (2)
Final quality check: RIC’s are only loaded if RFID tag can be programmed!
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Q4: Other Supply Chain Benefits?
Once Farm Dairy and DC Maasdam also implement scanpoints, a commonly shared RTI
system enables asset management, pooling, efficient transport, and quality management
on the RIC pool. 29
Current status
Entire pool of good RIC’s are tagged: approx. 30.000 RIC’s!
Producing RIC’s with automated SSCC to SAP: all route 2020 objectives were met!
RTI management for RIC’s in start-up: returns of empty RIC’s now possible.
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