201104 food manufacturing and automation show
DESCRIPTION
This presentation was given the 2011 Food Automation and Manufacturing Conference in Palm Beach, Florida. The presenters were Tom Nessen and Jon Cowan from Plex Systems. The presentation discusses the key components of a Food Safety Management System.TRANSCRIPT
How do you achieve compliance, improve efficiencies and gain competitive advantage?
The Question…
what’s in a number?these numbers tell a story about
food safety
50
10
500
1
what’s in a number?these numbers tell a story about
food safety
a single food product may contain over 50 ingredients,
where many ingredients are sourced globally and have been touched by 10 or more business entities.
a single manufacturer may have over 500 unique suppliers of ingredients,
and it only takes 1 incident to destroy a company.
2006
2007
2008
2009
2010
total numberof food recalls 200
0
600
400
800
global food safety initiative (GFSI)
safe quality food (SQF)
food safety modernization act (FDA)
ISO 22000
bio-terrorism act of 2002
british retail consortium (BRC)
USDA
how can
manufacturers comply?
Quality SPC
PlantMaintenance
Fragmented Data Sources
Traceability
OEE
DocumentControl
HACCP
HR – Skills Matrix
ComplianceManagement
the status quo
instant traceability
&recall mgt
food quality&
electronic HACCP
ERP
manufacturing operations
management system (MOMS)
instant traceability
&recall mgt
food quality&
electronic HACCP
ERP
• shop floor data collection• human machine interface (HMI)• mobile device operations • OEE reporting • rejection tracking• machine integration (SCADA)• allergen control• production scheduling• pick, pack & ship
MO
MS
MO
MS
Control Panel
Control Panel
Control Panel
ProductionRecording
ProductionScheduling
BarcodeLabeling
Control Panel
ProductionRecording
ProductionScheduling
BarcodeLabeling
QualityReporting
HACCPReporting
Control PanelPlant & Quality
Bulletins
ProductionRecording
ProductionScheduling
BarcodeLabeling
QualityReporting
HACCPReporting
Control PanelPlant & Quality
Bulletins
MaintenanceWork Orders
GaugeCalibration
Control
ChecksheetHistory
ProductionRecording
ProductionScheduling
BarcodeLabeling
QualityReporting
HACCPReporting
Control PanelPlant & Quality
Bulletins
MaintenanceWork Orders
GaugeCalibration
Control
ChecksheetHistory
DocumentControlAccess
ProductionRecording
ProductionScheduling
BarcodeLabeling
QualityReporting
HACCPReporting
Control PanelPlant & Quality
Bulletins
MaintenanceWork Orders
GaugeCalibration
Control
ChecksheetHistory
DocumentControlAccess
ProductionRecording
ProductionScheduling
BarcodeLabeling
QualityReporting
HACCPReporting
Time ClockTraining
OSHA Reporting
EmployeeInnovations
PLCIntegration
MO
MS
Enabling mobility
MO
M Enabling OEE
• HR – skills matrix• visitor log• supplier approval & scorecarding
• accounting & finance • advanced product costing• CRM• maintenance management• purchasing
traceability&
recall management
manufacturing operations
management system (MOMS)
ERP
food quality &
electronic HACCP
• HR – skills matrix• visitor log• supplier approval & scorecarding
• accounting & finance • advanced product costing• CRM• maintenance management• purchasing
traceability&
recall management
manufacturing operations
management system (MOMS)
ERP
• embedded document control• compliance management• electronic HACCP • checklists / SOP’s• corrective & preventative action • critical control point alarming• SPC charting• electronic signature• workflow
food
saf
ety
eHAC
CP Enabling eHACCP
Enabling eHACCP
Enabling eHACCP
Enabling SPC
• HR – skills matrix• visitor log• supplier approval & scorecarding
• accounting & finance • advanced product costing• CRM• maintenance management• purchasing
Instant traceability
&recall mgt
ERPfood quality
&electronic
HACCP
manufacturing operations
management system (MOMS)
• HR – skills matrix• visitor log• supplier approval & scorecarding
• accounting & finance • advanced product costing• CRM• maintenance management• purchasing
traceability• graphical product genealogy• extended supply chain tracking• lot trace and trace• allergen tracking
• reduce scope of a recall• quickly contain tainted product
ERPfood quality
&electronic
HACCP
manufacturing operations
management system (MOMS)
• Bleached Enriched Wheat Flour– Wheat Flour, Niacin, Reduced Iron, Thiamine Mononitrate, Riboflavin, Folic Acid,
• Candy Pieces– Dark Chocolate - Sugar, Chocolate liquor, cocoa butter, butter oil, soy lecithin, vanillia– Sugar, Yellow #5 Lake Yellow, Yellow # 6 Lake, Blue #2 Lake, Red #40 Lake, Blue #1, Yellow
#6, Yellow #5, Blue #1, Gum Arabic, Corn Syrup– Confectioners Glaze - Carnauba wax, beeswax and shellac
• High fructose corn syrup• Butter
– Pasteurized cream, water, lactic Acid
• Sugar• Shortening
– Canola Oil, Hydrogenated cottonseed oil, citric acid
• Eggs
• Contains less than 2% of 6 other ingredients
what’s in this cookie?traceability
traceability
traceability
traceability
ERPInstant
traceability&
recall mgt
• HR – skills matrix• visitor log• supplier approval• accounting & finance• advanced product costing• CRM• maintenance management• purchasing
food quality&
electronic HACCP
manufacturing operations
management system (MOMS)
food
saf
ety
traceabilityERP
• HR – skills matrix• visitor log• supplier approval• accounting & finance• advanced product costing• CRM• maintenance management• purchasing
• embedded document control• compliance management• electronic HACCP •checklists / SOP’s• corrective & preventative action •critical control point alarm• SPC charting• electronic signature• workflow
• graphical product genealogy• extended supply chain tracking• lot trace and trace• allergen tracking
• reduce scope of a recall• quickly contain tainted product
MO
MS
• shop floor data collection• human machine interface (HMI)• mobile device operations •OEE reporting •rejection tracking• machine integration (SCADA)• allergen control• production scheduling• pick, pack & ship
Instant traceability
&recall mgt
ERPfood quality
&electronic
HACCP
manufacturing operations
management system (MOMS)
enterprise food safety
management & ERP
Research
Maps
Business Software
“The Cloud”
ITEM On Premise PLEXSoftware Up-front; expensive;
Database, Application, Middleware, Server OS; CALS
Included
Hardware Up-front and expensive; Servers; backups; disaster recovery; cooling systems; test and production system
Included
Customization Customer managed; inhibits upgrades; costly. Becomes Standard
Versions and Upgrades
12-18 month release cycles. Must stay current to get support. Upgrades difficult and costly
Always on the latest version w/ Opt-in enhancements
Productivity Lower – can’t access system remotely Higher – Workers access system anytime, anywhere
TCO Higher – IT Operation (security DBA, report writing, developers, etc.), Support costs
Lower –Optimize IT Operations; more efficient support
Flexibility Tougher to adapt business system to changing business climate
Easy to adapt to changing business climate
Benefits of Cloud
twitter:
blog: foodsafteymanagement.wordpress.com
Jon Cowan – [email protected] Nessen – [email protected]