How factory automation can improve food safety outcomes
Factory automation solutions are often referred to as manufacturing execution systems (ESMs). For those of you frustrated with making sure your manufacturing teams comply with your food safety management system, don't take the above literally.
An MES is a factory-based system that automates plant operations.
To do this, it provides plant employees with detailed instructions throughout the production process and by automatically recording associated activities. It interacts with factory control systems such as scales, CIP and ERP systems - reducing manual administration and paperwork.
Food companies with a large number of products or complex manufacturing operations should reap the most benefits. The main commercial engines for the installation of an ESM are:
What does an ESM usually do?
MES manages all production and storage areas for raw materials, ongoing work, and finished products. It can also communicate with ERP systems for maintaining production records and capture additional information not captured by ERP systems such as containers, bins, knives, buckets, trays used, etc. All of these elements can be configured and plotted on an MES system.
During the production process, the ESM assists operators by guiding them step by step in their work instructions, telling them which equipment to use, capturing scanned details or item numbers of the equipment used. As a result, the ESM may alert users if they are trying to use incorrect equipment or if the equipment they propose to use poses a risk of allergenic cross-contamination. Links with factory specifications and finished product specifications can ensure that all customer specifications are met. Quality issues can be captured and referred to as supplier monitoring systems.
Checklist and PenImage
The traceability is based on the above. Instead of seeing only the traceability of the materials, MES shows for each production cycle, what materials were used, by whom and in which containers they were placed, what equipment was used, the cleaning records of the resulting equipment into a complete chain of events from start to finish.
When ingredients need to be weighed, distributed or mixed, the ESM can be linked-to scales and guide the operator step by step and follow the weigh-in to a target weight or a countdown to zero.
Links to finished product specifications and packaging copying systems can ensure that correct labels are applied to the packaging.
Conclusion
MES will not be suitable for all sites. There are substantial benefits, but cost-benefits need to be carefully assessed as a complete plant-wide ESM will require substantial investment and management commitment over several years.
An MES is a factory-based system that automates plant operations.
To do this, it provides plant employees with detailed instructions throughout the production process and by automatically recording associated activities. It interacts with factory control systems such as scales, CIP and ERP systems - reducing manual administration and paperwork.
Food companies with a large number of products or complex manufacturing operations should reap the most benefits. The main commercial engines for the installation of an ESM are:
- Improved quality control procedures.
- Improved traceability
- Increase the ability to capture more details about plant operations
- Less dependence on individuals
- Interaction with other systems
What does an ESM usually do?
MES manages all production and storage areas for raw materials, ongoing work, and finished products. It can also communicate with ERP systems for maintaining production records and capture additional information not captured by ERP systems such as containers, bins, knives, buckets, trays used, etc. All of these elements can be configured and plotted on an MES system.
During the production process, the ESM assists operators by guiding them step by step in their work instructions, telling them which equipment to use, capturing scanned details or item numbers of the equipment used. As a result, the ESM may alert users if they are trying to use incorrect equipment or if the equipment they propose to use poses a risk of allergenic cross-contamination. Links with factory specifications and finished product specifications can ensure that all customer specifications are met. Quality issues can be captured and referred to as supplier monitoring systems.
Checklist and PenImage
The traceability is based on the above. Instead of seeing only the traceability of the materials, MES shows for each production cycle, what materials were used, by whom and in which containers they were placed, what equipment was used, the cleaning records of the resulting equipment into a complete chain of events from start to finish.
When ingredients need to be weighed, distributed or mixed, the ESM can be linked-to scales and guide the operator step by step and follow the weigh-in to a target weight or a countdown to zero.
Links to finished product specifications and packaging copying systems can ensure that correct labels are applied to the packaging.
Conclusion
MES will not be suitable for all sites. There are substantial benefits, but cost-benefits need to be carefully assessed as a complete plant-wide ESM will require substantial investment and management commitment over several years.
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