Managing the variety of nature

By Rainer Weißenberger

A company’s information logistics must combine all aspects of production and materials management. Today’s ERP systems can do much more than simply depict the flow of materials and values. ERP systems for the food industry integrate specialised systems for recipe creation, production optimisation, and laboratory information. This makes it easier for small and medium-sized companies in particular to truly rely on integrated business processes.

A fruit processing facility processes natural raw materials (fruits and vegetables), which by their nature come in a range of different quality levels and quantities. The raw materials must be processed using conversion and mixing processes to create products for the food industry that are conform to precise specifications. These include fruit juice concentrates for beverage manufacturers or fruit preparations for the ice cream or baking industry, for example. All products have recipes that are translated into manufacturing instructions.

One of the recipe system's tasks is to establish whether a recipe adheres to certain internal or external (i.e. customer) specifications on the basis of the ingredients in the recipe components. If this system operates independently of the ERP system evaluations and information linking are only possible to a limited extent or else have to be performed by means of a third system.

Integrating the recipe management system into the ERP not only makes it possible to use more data such as costing and lot information, but also include, for example, characteristics-based mapping of a flexible, freely-configurable formula management system and, therefore, a know-how management system for product development.

The system links, controls, and documents the distribution and product development processes by means of electronic workflows - from the customer enquiry and feasibility study stages, to initial samples, right through to order production, product lifecycle management, and change management. This means that real data from the ERP system (relating to unit costs) can even be accessed for preliminary costing of the development recipe.

But product development is just one area to benefit from integration: Data can also be extracted from the recipe in the laboratory when creating inspection plans.

What is more, product information and specifications based on data from the product development department and laboratory can be created at virtually the touch of a button and, thanks to integration, can be accessed by the purchasing, sales, and production departments.

The resulting production protocol incorporates not just the recipe components themselves, but also customer stipulations concerning fruit content, for example. The machine centre enables production orders to be entered quickly and control over the processing chain as a result, from raw materials to semi-finished products, right through to the point at which the tank is filled.

In the case of production orders the individual components are allocated while also ensuring compliance with the specified limits for the end product based on all the components involved. Depending on the Brix value, for example, a greater quantity of lot A than of lot B may be required. Indeed, the system may even be able to generate a suggestion for all the recipe components at the touch of a button.

Transparency is ensured in lot concepts that integrate lot monitoring and status management throughout all stages of production, from the original materials to the final product and vice versa, and which encompass management of tanks, containers, as well as various other forms of packaging.

Biography

Rainer Weißenberger is CEO of YAVEON AG. He has long term experience in fully integrated information logistics for batch processes and ERP systems.