Performance. Sustainability. Compliance.
Customer Name Presentation – July 2012
Use of Materials
The following materials are provided solely for purposes of evaluating a potential business opportunity, and with the mutual understanding that they will not be copied, re-distributed, or used for any other purpose.
Vigilistics Confidential.
Vigilistics: Enterprise Process Reporting
• Process Monitoring, with dashboards and KPI
• Scientific Analysis, with enterprise benchmarking
• Scalable, analysis enriched data; easy to use and share
• Process and Quality reporting, with FDA validation
Vigilistics Confidential.
Dairy Processing Challenges
The Use of Technology to Increase Transparency and Shorten Corrective Action Cycles means less Shrink
Record Keeping under
FSMA
Process Monitoring and
Reporting
Exception Management
Corrective Actions
Benchmarking, Variance and Root Cause Analysis
Vigilistics Confidential.
Comprehensive Suite for Dairy
Vigilistics Confidential.
Compliance (CIP, COP) Material Loss/Yield Traceability Chemicals Utilities Analytics
Milk-Loss Overview
Configurable, Maintainable System• Configurator for automated PLC/HMI integration• Units, Areas, Inventory • Product Types and Classes, with standards• SKUs, Molds, target weights
Designed for Milk Processors• Bulk Receiving and Loadout, Inventory, Quality, Pasteurized
production, Filling Room, Rework, Blow Mold and SKU weight, Volume and BF variances, Performance by Hauler, or Operator . . .
• Accounting Adjusting Entry support (One Record!)• Production Planning included• Configurable real-time Alerts • Live Plant-wide and drill-down Views
Vigilistics Confidential.
Milk-Loss Focus Area
Vigilistics Confidential.
Misc.
Receiving
Mix / Blend
Piping
Filling / Packaging
20%
10%
10%10%
30%
20%
Pasteurizing
Receiving
• Problem: • Farm samples and declared weights• Supplier Variances in volume and BF• Operator logs and process records differ from accounting
• Solution:• Automated or Keyed record entry, with Accounting adjusts• Metered Volume vs. Declared, integrated BF tests• Real time notifications of variances
• Opportunity:• Average Milk-loss of 0.25%, BF variance of 0.1%• One Record = Less headache!
Vigilistics Confidential.
Standardization
• Problem: Batch Standardization Lack of reporting on batch details Lack of visibility to batch frequency and losses Too much finger-pointing over shortages
• Solution: Integrate lab results, calculate BF standardization
loss Easily accessible reports for Production Planning
• Opportunity: Big BF opportunity depending on mix $10,000/month in Standardization and
Improved Production Planning
Vigilistics Confidential.
Filling Room
• Overfill and Throughput Lack of standards or control of overfill Managing production against ordered quantity Achieving throughput
• Solution: Real Time Weights Sampling, with predefined
targets Production Planning by SKU Real-time view of buffer storage and production
• Opportunity: Up to 0.5% in reduced overfill
Vigilistics Confidential.
Engineering
Vigilistics Confidential.
• Old, hard to maintain process controls Not practical to add new features Current process control strategy not supported by
existing controls
• Solution: Process Reporting can be an effective means of
augmenting current control systems Measure/standardize pasteurizer change-overs Integrate Allergen Awareness into CIP process
• Opportunity: Extend the useful life of current control systems
Blow Mold Management
• Process Variances Inconsistent weight of blow molded containers
• Solution: Real-time weight collection for each mold Identify performance by Shift by Operator
• Opportunity: 1 gram per 1 gallon jug x 80,000/day = $150/day Or, around $40-50,000/year!
Vigilistics Confidential.
Administrative Reporting
• Headcount dedicated to daily reporting Handwritten logs problematic for SQF and QA Transposing logs into Excel and into reports Production Planning repeats the laborious process
• Solution: Automated reporting with Acctg
Review/adjustments Integrated Production Planning Result: One Record of Production!
• Opportunity: Free up one headcount to do productive work
Vigilistics Confidential.
Audit/Inspection Readiness
Vigilistics Confidential.
• Too much paper! Time spent filing and retrieving, and space for storage Increasing need for auditable records What is the plan for documented process for FSMA?
• Solution: One Record, automated online reports Ability to delegate Audit Readiness to Supervisors
• Opportunity: How many hours and days would you save
annually? Improved Quality Ethic throughout the staff
Managing Plant Performance
Vigilistics Confidential.
• Yesterdays loss number isn’t actionable No ability to assign loss to operating area Operations and Accounting never agree Problems within the day . . . If I had known!
• Solution: Live view of Receiving, Pasteurizing, Filling,
Loadout Define real-time variances to drive Exceptions Integrated, single record between Ops and Acctg.
• Opportunity: You get what you measure -- >0.5% more
bottled
Managing for Continuous Improvement
The Future
Vigilistics Confidential.
Connected, Integrated Plant Plant reporting to Enterprise Standards Anytime Inspection & Audit Status Agility and Supportability Shared Best Practices
Next Steps
• Select KPIs • Set initial Benchmarks • System Pilot
Automated, Accounting Supported, Real-time and Daily Performance Reporting
Vigilistics Confidential.
Performance. Sustainability. Compliance.
Thank You
www.vigilistics.com (949) 900-8380