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Performance. Sustainability. Compliance. Customer Name Presentation – July 2012
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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.
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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.
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Dairy Processing Challenges The Use of Technology to Increase Transparency and Shorten Corrective Action Cycles means less Shrink Vigilistics Confidential.
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Comprehensive Suite for Dairy Vigilistics Confidential. Compliance (CIP, COP) Material Loss/Yield Traceability Chemicals Utilities Analytics
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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.
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Milk-Loss Focus Area Vigilistics Confidential. Misc. Receiving Mix / Blend Piping Filling / Packaging 20% 10% 10% 10% 30% 20% Pasteurizing
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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.
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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.
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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.
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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
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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.
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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.
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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
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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
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Managing for Continuous Improvement
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The Future Vigilistics Confidential. Connected, Integrated Plant Plant reporting to Enterprise Standards Anytime Inspection & Audit Status Agility and Supportability Shared Best Practices
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Next Steps Select KPIs Set initial Benchmarks System Pilot Automated, Accounting Supported, Real-time and Daily Performance Reporting Vigilistics Confidential.
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Performance. Sustainability. Compliance. Thank You www.vigilistics.com (949) 900-8380
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