System of operational planning and production control at the meat-processing plant

RPE “Metra” which is well-known as a weighing equipment manufacturer in meat-processing industry offers new approach to weight control system at plants with output up to 50 tons per day. Now we present our last development – soft hardware provided for data collection and operational planning of production tasks.

Provision of stable quality level together with process costs reduction at the modern meat-processing plant can be achieved mainly by efficient running of material resources planning and control system. Meat-processing industry peculiarity is that large volumes of meat stuff and half-stock are processed during operation. Almost all tecnological procedures are concerned with weighing of used stock. Process lines of various meat-processing plants differ from each other, but the whole production cycle is typical for most meat-processing plants, sausage departments and workshops. It can be conditionally divided in three main processes:

1. preparation and stuff delivery from the stuff storehouse,
2. production of articles,
3. finished product transfer to the storehouse for customer orders formation.

Suggested system of operational planning and production control consists of two subsystems:

• operational production planning (consists of computerized workplaces united in a network, which cooperates with existing accounting system),
• work tasks control (consists of control and weighing posts network connected to the plant’s information network).

Control post (CP)

Post of work tasks control is designed for operational distribution of production tasks obtained from operational planning system within the workshop (section), and for control of work tasks fulfillment by the section as a whole and by separate workers. CP is a workplace of section master,foreman or shop manager.

CP equipment: control post with touch screen, built-in bar-code scanner and bill printer.

Main algorithm of task assignment by the master

1. Scanner reads personal mark.
2. List of all forcemeat preparation tasks in order given by the director of operations is displayed at CP screen. % of fulfillment and responsible person (if the task is distributed) is displayed for each task.
3. The program offers to open forcemeat preparation task (to see task elements).
4. Master chooses one of undistributed task and assigns executor, reading his personal mark by scanner or selecting him from the list.
5. Then master prints the task and gives it to the executor.

Weighing post (WP)

WP is designed for registration of stuff, material and finished products weighing during production process, i.e. for execution of production tasks and their parts received from the system of operational planning and control posts. A worker who fullfil the given production task operates the Weighing Post.

WP equipment: scales, scale terminal, bar-code scanner and bill printer.

Main algorithm of task registration by executor:

1. Tare with product is weighed, and personal mark is read by scanner;
2. Executor name is displayed at the panel; the program offers to enter the task item;
3. Scanner reads bar-code of task item;
4. Stuff title and gross weight are displayed at the panel;
5. Bar-code corresponding to tare weight is read from tare label;
6. Title, net weight, gross weight are displayed at the panel;
7. Scanner reads bar-code of “OK” command from virtual keyboard;
8. WP registeres task (task item) fulfillment and, if necessary, prints title label of the given task in compliance with format;

Software

The system has client/server architecture. MS SQL Server is used as a database management system. Due to this structure, the system is simple for installation and administration.

Thanks to integration with programs “1C Enterprise” and “1C Trade ahd storehouse”, the system uses 1C-program data as on-line data for automated planning, and it simultaneously add data, collected during production process, to 1C-programs for financial planning. Thus, departments that do not directly participate in production process can efficiently control system data and process it in their customary programs.

These systems can be exported in MS Word and MS Excel.

Most enterprises already have systems of production planning, task assignment to sections and each worker, and systems of stuff and finished product movement control. They also have a control system which operates as an information system and does not allow real-time control of working tasks.

The system proposed by RPE “Metra” is intended for production control by leaders at various levels.

The system offers:

• to general manager – instrument for strategic task realization;
• to production manager – instrument for planning and management decision-making;
• to production engineer – instrument for provision of set product composition and production technology;
• to production foreman – instrument for task assignment and operational control.

The system covers the full cycle of production control, including:

• Planning
• Fulfillment
• Control
• Analysis

The term “production control” means: setting of real goals and tasks, production process (workplaces) provision with necessary resources, assignment of volume- and time-balanced tasks based on standards and technological processes to subordinates (production sections), operational control of tsks fulfillment, and, if necessary, timely alteration of tasks.

Data collection should:

• Exclude input errors (you can trust the data),
• Provide timely information update and provision (data is actual),
• Provide required volume, accuracy and form of introduction (data corresponds to the management task).

Data collection

If even one of these requirements is not met, data application results in the risk of false management decision and can be more harmful, than useful.

Moreover, it is necessary to compare costs on data collection with benefit of its application.

There are two types of input errors: intentional and unintentional.

In the existing system data concerning inventory holdings movement is collected by means of weighing at electronic scales. Weighing results are visually read by the worker and entered in logs, notebooks or on sheets. Then this data is entered in computer, sometimes by another worker. Disadvantages of this process are evident:

• Double input increases error probability.
• No efficiency. Data comes to the manager with several hours delay, or even days.
• Time consumption of production workers or administrative personnel which should input data in the computer are unavoidable.

In the suggested system data collection is automated and executed together with weighing, so listed disadvantages are either absent or can not substantially influence, namely:

• Automatic input of weighing results considerably reduces error risk.
• Full efficiency.
• Minimum time and strength costs for data collection.

Only true data is not enough for efficient management. It should be compared with existing plans to find discrepancies. Thus, analysis is needed.

Analysis

In the existing system data for analysis is collected in the following form:

• Record number in order,
• title (stuff, half-stock, products),
• quantity,
• date (time),
• responsible persons.

Thus, we know, how much and which material was spent, how much and which product was manufactured, who and when (date – time) produced this item. However, we can find out discrepancy between planned and actual data by means of any accounting system, but we can not discover the reason of discrepancy as we collect data not of production process, but of resource movement. As a rule, the manager can find out reasons of discrepancy on the basis of subjective opinions of his subordinates (foreman of workshops, sections and other production departments). This analysis does not answer the question “Why the plan was not fulfilled?”, so data collection system itself is inefficient.

The supposed system is based on hierarchical structure of production tasks. Each task can generate a chain of lower level tasks. The system allows to control each task fulfillment.

During freight weighing, the system registers task fulfillment, so you can always check which task was not fulfilled or unduly fulfilled. This approach allows to discover problems and their causes, which is the main goal of analysis.

So, analysis is made, problems and their causes were discovered.

Control

• Operative task is an ability to correct control and performance errors quickly by means of real-time production tasks rescheduling. Operative tasks are solved by workshop manager and foremen of production sections.
• Tactic task is an ability of timely production process modification directed at product quality increase and process costs reduction. Moreover, reaction on seasonal demand fluctuation is also a tactic task. Tactic tasks are solved by production engineer and director of production.
• Strategic task is an ability of output volume, assortment and stock-list modification, new product types introduction and new market development. Strategic tasks is the prerogative of the owner and general manager.

In the existing system engineering process is controlled on the basis of previous experience and insight. Production is conservative, engineering process modification for problems solution is of evolutionary and prolonged nature. For found problems elimination, it is necessary to use cut-and-try methods and wait for a long time. Common protection method from manufacturing problems consists in store increase, which increases production stangnancy even greater, worsen quality and rises costs. Leaders do not actually manage production, it completely depends on experience and insight of production engineer and foremen, who consider leaders intervention in control process as a trouble.

Supposed system allows to provide operational control of production tasks, rapid replacement and new items introduction, production volume modification in compliance with market requirements.

• In operative level the system allows to correct control and performance errors quickly by means of real-time production tasks rescheduling.
• In tactic control level the system allows to solve two main problems:
  • Product quality increase due to operative system of data collection and analysis,
  • Process costs reduction due to stock cutting down. It is possible because of detailed planning and control of material resources consumption during production.
• In strategic level the system allows to leader to modify output volume and product range quickly in compliance with variable customers requirements. It provides flexible reaction on market conditions, which assures prosperity of the plant.

It is difficult to make incorrect decision when you have this control instrument.

	Layout of meat-processing plant with the system of operational planning