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Premium Deli Meat Processor Reduces
Errors and Gains Visibility by
Integrating Radley’s x/DC with Scales & MES System
Imagine the ability to track lot, part, quantity,
temperature, date, serial number, vendor - any data element
- all with one single scan… Gaining
visibility to more information than ever before… Processing
thousands of transactions with only hundreds of scans…
After implementing Radley’s x/DC Automated Data Collection
Solution in all 5 of their processing facilities, there is
one premium deli meat processor for whom this is now a reality.
Product classifications
were being recorded manually on spreadsheets - a very cumbersome
process; and because the process was so cumbersome,
some necessary data elements that were needed for
traceability were not being recorded. In addition, product
data was being recorded only at the end of the process, disturbingly,
leaving them without an accurate view of Work in Process
on the production floor. And after implementing their new
ERP System, they realized that they would need to process hundreds,
if not thousands of data elements per day.
All of these
factors convinced them that robust automated data collection
was a necessity. Their homegrown distribution
system and manufacturing execution system (MES) were already
in place, so a data collection solution provider
that could provide seamless integration into these systems
simultaneously became a requirement as well.
Phase I of the implementation began with purchase order processing (Receiving), and Inventory, using bin transfers, warehouse transfers, and issuing and returning of Material to the shop floor using Material Increases and Decreases.
When inventory is received, they scan an industry standard UCC bar code to get the DUNS Number, serial number, part number, lot, temperature, and date. Products received are then weighed on a scale that is integrated with X/DC. They have almost 40 scales on the shop floor that are all integrated to X/DC to process many of their transactions. To reduce labeling errors all scales are linked to label printers and labels are produced at the point of weighing. Since their legacy distribution system is an integral part of their business process and is linked to their financial system, all transactions are validated by X/DC against the distribution system before the ERP system is updated. This validation triggers printing of a label that verifies that the transaction was processed correctly.
Phase II of the implementation involved the integration
to their Process Manufacturing module. Automated transactions
include Material Issues, Material Returns, Stock Conversions
and Job Outputs. Implementing Radley’s IntelliLabel solution eliminated the need for multiple scans. IntelliLabels associate all of their critical information, such as temperature, weight, lot, part, and date all in one scan, reducing the number of physical scans an employee has to complete to obtain all the needed product information. Radley’s
IntelliLabel solution also aids in the ability to trace product
back through the system.
This premium deli meat manufacturer is now benefiting from
the ability to have an immediate and accurate snapshot of their
WIP inventory on the shop floor. They have also reduced errors
now that all transactions are validated and integrated with
their ERP, distribution system, scale equipment and MES. Their
greatest benefit has been the increase in their yield from raw
material, labor, production and machine time. [ PLC
/ Machine Integration ] |
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