Transforming a meat processing plant into a smart factory is not just about adding the latest automation technology. In fact, a modern meat factory is planned to be ‘smart’ right from the design phase. The result of this thorough planning is a facility with seven specific qualities.
1. It is built around a data-based management cockpit
You can only control what you can measure – this is the ground rule for new build and extension projects. The single most important element of a smart meat factory is its central nervous system, which has ERP at its core. With the correct, accurate and up-to-date measures, indicators, and KPI, you will be able to monitor performance, identify problems and intervene systematically in order to further optimise operations. There is obviously a reason why leading businesses in this industry are not only meat factories, but also data factories.
2. It enables constant and seamless flow of data
A smart meat factory tracks data at every entry point and processing step, from the delivery of raw materials to the shipping of finished products, and uses technologies that help software, hardware and people communicate efficiently with one another. Today, machines and ERP systems can easily communicate with each other, achieve complete transparency of processes, monitor performance, and compare planned and actual data.
3. It puts IT at the forefront from the design phase
Building a smart meat factory is, first of all, an IT project, whether it is a new build or an extension. While you should work closely with your building contractor to ensure that the design reflects your vision, you should also keep in mind that working with the right IT partner early on is of strategic importance. Making the wrong choice and having to replace an ERP system may have much more serious consequences than investing in the wrong machine.
4. Its physical space is efficient, flexible and future proof
As a producer of meat products, you also have to optimise the space around which your process flows. In a smart meat factory, however, the ‘physical’ implementation is not only based on your current processes. It is very difficult, if not impossible to know today what you will produce in five or ten years and what technologies you will use. Therefore, you should not block your spatial flexibility, especially in areas such as production, logistics, picking, and warehousing.
5. It uses automation to close the loop between goods and data
Once the right IT and physical infrastructures are in place, a smart meat factory takes full advantage of the latest automated and robotic technologies. The greatest potential currently lies in intralogistics, where many meat companies have developed groundbreaking standards in automated packing facilities, semi-automated picking systems, automated weigh price labeling, and robotic warehouses.
6. It is ready for future innovations
A smart meat factory is well-positioned to introduce new technologies in the future, such as Artificial Intelligence (AI), “brain interfaces” where operators literally control their production machines through mind-reading, or advanced image recognition systems that can detect contamination and damage in meat more precisely than ever. When a facility is designed to adapt to future solutions, innovating at a rapid pace becomes much easier.
7. It is not built as an island
A smart meat factory is built as part of a value chain that extends beyond its walls. It is designed to be optimised and flexible and adapts quickly to changes in market prices and consumer trends or to unexpected disruptions in other production centres of the enterprise. It is constantly exchanging information with other business units of the company, suppliers and customers. It operates always at the limit of its resources, but not of its capacity. This way, it achieves a higher average capacity utilisation, a better use of production means, and lower unit costs.
Planning early saves costs of investments
Fully digitising a meat factory is not only possible, it also makes perfect business sense. Whether you are building a new facility or renovating an existing one, these seven success factors are an ideal starting point that will open up tremendous opportunities to realise cost reductions. Getting your digitalisation partner on board early on allows you to achieve cost savings in excess of $145,000 just by improving the interface coordination with machine and equipment manufacturers and by transparently assessing the offers of the service providers involved.
This is a sponsored post by CSB-System. For case studies from CSB-System, visit the website, YouTube or LinkedIn.
