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Dashboard data feeds growth

01 October 2017

As part of its new state-of-the-art poultry processing facility, Faccenda Foods has utilised a new production management system, using live dashboards, on each of its 15 processing lines. 

Faccenda Foods has to supply a wide and varied product range to retail and food service sector customers across the UK, often with same day delivery. As part of its investment in a new site, the company took the opportunity to introduce a new software system, supplied from Systems Integration (SI), to provide it with real-time data to improve and inform its operations. 

The business has already realised the benefits of being able to sharing data in an easy to understand format. Philip Davidson, Faccenda’s operations director takes up the story: “When there is easy access to real time information, it is possible to make in line decisions which deliver a positive performance difference to the operation. 

“From the moment we started to display information such as target weights for fixed weight products, scheduled processing times and giveaways against our defined targets on dashboards, our teams have been much more engaged. 

“Each line is now aware of how well they are doing and of any anomalies that are occurring. Friendly competition has emerged as one line aims to perform better than the other. As a by-product, staff share more knowledge and information and are more likely to proactively suggest changes to improve performance.

A positive impact
“This has had a positive impact on teamwork and has helped us to achieve much greater visibility of our performance through the processes undertaken to deliver a finished customer ready product. We use the real time information on yield, giveaway and productivity to drive the agenda and actions in our Short Interval Control, (SIC), shop floor meetings.

SI’s solution also helps to manage the company’s range of weigh price labelers and outer case labelling systems. This is handled centrally through the planning and scheduling team. “By doing this we have delivered 100% consistency in label design and integrity across the production lines,” continued Davidson. “Date and batch coding are governed by the system, negating the need for of operator input and so reducing risks resulting from human error. Over and under production of individual SKUs is therefore managed, reducing processing waste. As a result the operation is more efficient and is able to provide customers with greater reliability.

The company is currently looking at ways that it might be able to SI solutions in its ‘Ready to Cook’ operation. “As well as the standard systems we have at Telford managing operating parameters, batch and date coding through scheduling, we are developing a stock management system for pre-batching ingredients for production assembly runs,” said Davidson. 

“This, in turn, will give us 100% traceability through electronic data archiving, without the requirement for paperwork. We will also use the system to drive ingredient and packaging ordering direct with suppliers ensuring stock is maintained at optimum levels. In ‘Ready to Cook’ we will continue the roll out with our paperless QA solution, which we have implemented at Telford, where all checks are performed on connected devices and information is archived automatically.”

To date SI has integrated the labelling, quality assurance, weighing and various WMS systems used to transfer stock records for Faccenda Foods. Moving forward, it is now looking at how it can help the Faccenda team integrate other areas of the business, including its stock tracking system. “The main advantage of Faccenda Foods taking a modular approach to implementing our solutions, is that we have been able to train staff and embed each new module in a systematic way, ensuring it works, before moving onto the next phase,” said Rob Stephens, managing director at SI. “This has had clear benefits and delivered confidence to staff that have never used such systems before.” 

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