Industry 4.0 for the food and beverage sector

MES SYSTEM FOR THE FOOD SECTOR

Practically half of our clients in MESbook belong to the agri-food sector, where we have successfully solved key challenges in this sector, such as strengthening their Quality and Traceability system, reinforcing the food safety of the products they manufacture and/or package, as well as measuring deviations in their variable costs (raw material, labor and energy) to identify and quantify the cause of these deviations in €.

We connect all the actors in the factory (machines, people, systems, processes and product/raw material) so that, based on our extensive experience in factories and the sector in particular, our implementation methodology and our technology, we digitally transform the factory and provide our customers with real-time management, to manufacture more every day, with better quality and lower cost.

Challenges in the food and beverage industry

Maximize machine utilization.
Control of critical process variables.
Energy transition and sustainability.
Agile and paperless management.
Continuous improvement of its processes and products.
Reduction of indirect costs for the collection and management of data to convert it into knowledge and act faster based on reliable and objective information.

Reliability and robustness of your quality and traceability system for regulatory compliance and to minimize your NO-Quality costs.
Efficiently guarantee food safety in its products (control of CCPs).
Reduce manufacturing costs.
Identify and quantify shrinkage map.
Measurement of the performance of each raw material and assessment of each supplier's compliance with its specification.

MES food industry software solutions

Production system connected to machines and systems, operators, processes, and raw materials through multiple technologies (webservices, OPC-UA, barcode, NFC, RFID, etc.).
Digitalization of the Quality Plan and launching of factory control guidelines, according to the products manufactured and the lines where they are manufactured.
Automatic operator guidance and execution of the appropriate plant controls necessary for the quality assurance of each product.
Digital signature: Registration of controls and events relevant to traceability, with immediate interpretation of the quality result and alerts in case of any non-conformity, for quick launching of corrective actions.
Connection to Scada, vision, weighing, measurement and quality systems in real time, for data capture and interpretation of signals, consumptions or real quality condition.
Automatic capture of stops and reasons for them.
Activation of license plates for each raw material, at consumption locations at the manufacturing line for traceability tracking.

Connection to machines and visualization of production progress and Quality compliance by sections and machines.
Connectivity to sections in long lines to draw a shrinkage map and identify where in the process the scrap is occurring (and its cause), in order to launch immediate corrective actions.
Real time control of critical process points (temperature, ppm's, metal detector, etc.), through which trends and deviations from the set nominal will be controlled, applying traditional SPC.
Real-time visualization of plant KPI's: Quality, Productivity and Costs, by section, line, family and product and their deviations with respect to the objectives set.
Calculation of cost variances by MOD and shrinkage (process, overweight and purchase price), as well as the cause of variance in €.
Paperless factory management.
Digitization of the fundamental tools of LEAN Manufacturing

Benefits of implementing Mesbook in factories

REAL-TIME CONTROL

Real-time production control of the factory and the problems that occur, being able to act on them in real time.

Reliability of the quality system

Perform the management and pass the audits paperless, to achieve IFS and BRC accreditations, reducing time and costs associated with administrative tasks.

RESULTS CONTROL

Control over price variations in raw materials and the impact on the income statement.

Machinery control

Control of machine availability and performance. Savings in unnecessary investments.

Resource control

Optimization of the consumption of material, energy and human resources, as well as minimization of waste.

OEE CONTROL

Knowledge of where shrinkage occurs in the process, either between sections or on a line, as well as its quantification in €.

cONTROL OVERCONSUMPTION

Intelligent system for the control and monitoring of material overconsumption and deviation in each OF along the entire value chain, with alerts for action.

Traceability control

Traceability throughout the entire production processfrom the manufacture of the semi-finished product to the packaging of the final product..

COST CONTROL

Control and optimization of variable costs and visualization of deviations against the company target. Saving indirect costs related to data capture and management in the factory to convert it into information and knowledge.

PERFECT RECIPE

Potential to link any variable that has participated in the process and achieve what is defined as Golden Batch (Perfect Recipe, optimization of waste, direct labor costs or quality) by means of Machine Learning and advanced analytics.