food processing software - frontmatec...s2 - your modern scada system s2 is a modern scada system...
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Food Processing Software
With GOSystems you get
▪ Effective processing control ▪ Overview of your value chain ▪ Advanced production planning ▪ Integration between systems
Automation for lowering costs and increasing profits
Managing the complete value chainProduction and distribution companies in the food industry have unique and comprehensive management needs that cannot be solved in a standard ERP solution or through a traditional automation solution.
Frontmatec has developed the MES system GOSystems, which meets those needs. GOSystems is an integrated and flexible system which provides you with an intelligent production control software suite that enables you to monitor and manage the complete pro-duction value chain, from the reception of live animals to the dispatch of the finished product.
GOSystems provides real-time monitoring and control of all critical key performance indicators (KPIs) related to every stage of production, including yield, throughput and efficiency, giveaway, loss of sales, stock levels, movements, traceability and profitability.
Based on an agile framework design that provides maximum flexibility for processors of all scales and
sizes, ranging from small and medium-sized enterprises to plant-wide systems, our solutions can share data with accounting or ERP systems for order processing and inventory management, as well as with customers, sup-pliers and product managers.
Integrated and flexibleFrontmatec GOSystems is an integrated and flexible system that supports a wide range of Frontmatec processing equipment and systems to provide the most integrated processing solutions available and open fresh opportunities in production management.
A real-time solution developed using latest technology from Microsoft, our suite runs on a Microsoft SQL server database.
For further information: frontmatec.com/en/control- systems/meat-solutions
1. Slaughter line
Control of the animal reception process is vital throughout the meat industry, to reduce loss and achieve full control over raw material and how it is processed. On reception into the system, supplies are checked for quality and identified according to certain criteria, on which decisions are based at later stages of processing. Information such as animal ID, fat thickness, age, breed, PH value and so on comes from various system devices such as our Frontmatec grading equipment.
Benefits ▪ Full animal traceability (e.g. origin farm, country,
slaughterhouse or/and individual animal) ▪ Instantaneous reports on, input by yield group, grade
and breed ▪ Applies simple data collection methods to ensure fast
reception of animals ▪ Monitors supplies for product quality and supply
accuracy ▪ Monitors and controls the reception process
2. Cutting and deboning
Effectiveness in this area is decisive for profit and loss in the production floor. GOSystems provides state of the art planning, inventory and sales information necessary to determine the required primal parts for cutting and deboning as precisely as possible. The solution further provides permanent target actual comparisons directly to the operator’s specific performance assessment.
Benefits ▪ Produce on what primal parts as required ▪ Elimination of high cost inventory items ▪ Provides accurate operator feedback, directly related
to profitability
GOSystems focus areas
3. Order management & planningProduction planners at modern day food processors are under more pressure than ever to meet crucial delivery times.
GOSystems order management and planning software allows the planner to use a sale forecast accurately to ensure that raw materials are consumed as effectively as possible in accordance with current order status and current production capability.
Benefits ▪ Assists the production planning time frame ▪ Enables order specific packing and labelling ▪ Suited towards order-controlled processing lines ▪ Assists in minimizing stock levels by matching animal
characteristics to customer requirements more efficiently
4. Performance monitoring
In a meat plant, KPIs such as efficiency, quality and yield are vital to your business. Implementing GOSystems provides processors with accurate and reliable data to help improve performance and make decisions. Performance data is collected at predefined control points – e.g. at every operator station – where individual operator performance is monitored on indicators such as yield and throughput. GOSystems dashboards provides meat processors with a full view of their KPIs in real time.
Benefits ▪ Collects reliable and accurate production data ▪ Provides real-time access to KPI information ▪ Provides is a decision-making tool
Benefits ▪ Powerful, fast and easy to use ▪ Simplified labelling process ▪ Improved & quicker label designs ▪ Meets varying label design and language ▪ Control of centralized printer management ▪ Quality: Making sure the customers get the expected
quality, securing yield
GOSystems focus areas
5. Traceability
Meat producers can benefit financially from GOSystems which is designed to ensure food safety and quality. Traceability is at the forefront of food safety. GOSystems makes it possible to trace every product directly back to its source, implementing our system places meat processors in a position to act quickly and minimize potential recalls. The GOSystems traceability engine is built into every process step based on individual animal or batches for all production processes.
Benefits ▪ Collects reliable and accurate production data ▪ Provides real-time access to KPI information ▪ Minimizes the risk in the event of incidents
6. Label management
Accurate, easy-to-read, and scientifically valid nutrition and health information on food labels is an essential component of a comprehensive public health strategy to help consumers improve their diets and reduce their risk of diet-related diseases. Improved food labeling with GOSystems can provide consumers with easy-to-read nutrition and ingredient information that they can use to reduce their risk in food safety.
Benefits ▪ Supports the need to meet demanding delivery
requirement to the retail industry ▪ Supports, advanced packing, weigh price labelling,
warehouse management, order picking palletizing and dispatch processes
Benefits ▪ Single point of master data maintenance ▪ Continuous monitoring of customer orders ▪ Minimize complexity by using specialized systems for
specific tasks ▪ Improve response times ▪ Connect multiple sites ▪ Improved customer service
7. Outbound logistics
Meat processing factories today can be complex operational environments where critical decisions must be made fast and accurately. After all, on time customer deliveries could be at stake. Ensuring timely delivery is vital to customers, so it is crucial to have the right tools and equipment in place to manage all logistical challenges. GOSystems outbound logistics provides capabilities that are scalable and reliable, covering all processes from reception to proof of delivery.
8. Integration to other systems
GOSystems offers standard data interfaces for all your production data collected. Seamless non-stop integration with other systems safeguards operational continuity within the factory. At the same time, it ensures that ERP and planning systems can upload and work with data from GOSystems.
Digitizing processes saves time and moneyWith digitization, meat processors can reduce costs and increase quality: for example, scanning in picking reduces error rates and returns while it increases order fulfillment rates. Utilizing tolerance checks in batching for specific meat production can result in better quality and fewer rejects.
Reduce giveaway in cutting and deboningIT-aided online monitoring with permanent target-actual comparisons directly at the primal cutting line is a field-proven method. The central control instrument is exact weighing at cutting entry (AGOL,) and exit with accurate allocation of staff.
On the one hand, it facilitates control of the cutting yields, thus providing a documented basis for renegotiations with the vendor, for example if the lean meat content does not meet the requirements.
On the other hand, the entry enables employee-specific performance assessment which has an impact on the
determination of bonuses and thus on the payment of the operators or butchers on the line.
Industrial image processingTime and again, practice has shown that manual activities are not only inefficient and costly, but also exposed to hygiene risks. In this context, industrial image processing solutions have several advantages.
For example, take grading systems such as the Frontmatec BCC-3 which is based on advanced multi-view stereo imaging and grades in conformation and fat cover classes.
Currently, the image analysis is expanded to provide yield predictors of beef primals and detailed information about commercial cuts.
Why GOSystems?
Better recipes for more profit
In the meat industry, costs for material use account for 60 percent of sales revenues and are thus particularly high. Raw material prices are expected to continue to rise. Therefore, it is necessary to optimize recipes to achieve higher margins. Using GOSystems software producers can accomplish these tasks automatically. Con-sidering chemical and technological restrictions, they can calculate the most cost-efficient composition of recipes while maintaining constantly high-quality levels.
Advantages achieved by automation
▪ More productivity ▪ More profitability ▪ Better quality and lower contamination risk
Why GOSystems?
Secure batches for better marginsEven though today’s products are safer than ever before, traceability is still one of the most critical issues in the international meat industry.
The ultimate objectives are food safety and consu-mer protection. Investments in IT-aided traceability systems are based on economic calculus, even though monetary benefits are difficult to quantify. The va-lue of IT-controlled traceability systems is a huge wakeup call in the case of incidents, because they are capable of quickly identifying the affected batches and systematically eliminating the products from the supply chain. This reduces the macroeconomic damage of a recall to a minimum.
Automation for low costs in internal logisticsFor meat processors, investments in GOSystems automated logistics systems usually pay off quickly. GOSystems controlled automation solutions substantially contribute to reducing throughput and lead times, increasing delivery readiness and cutting costs.
Prepare for the futureDuring past years, the procurement of IT solutions for food processing has been steadily growing. Main drivers for this development are digitization of the food industry.
The strong growth of Frontmatec offerings does not come as a surprise, because of the increasing virtualization of production and business processes and their shift to more user-friendly platforms to enable more transparency and higher performance. Frontmatec achieve this by always remaining up to date with the latest Microsoft release platform.
GOSystems from Frontmatec food processing software is developed completely with the food industry in mind and its agile architecture is ready for the future of the industry and implementation of future trends such as Industry 4.0, IoT (Internet of Things) and Big Data.
The following are the most successful areas of improvement as a result of effective project implementation: ▪ 70% improvement of levels of service automation ▪ 72% reduced costs ▪ 73% improved business performance
S2 - your modern SCADA system
S2 is a modern SCADA system based upon standard Microsoft technology. The system comes with an integrated maintenance module and full database access which gives you the opportunity to save historical data.
Other solutions: S2 SCADA finds the reason behind your production stops
Have you ever considered the value of 10 lost production hours?
▪ In direct wages ▪ Replanning of production ▪ Work overtime ▪ Bad customer experience
Production down time will never come back – it is lost forever. Therefore, it is always crucial to find the reason behind your production stops - fast. Our SCADA system, S2, can help you with exactly that.
Fast problem solvingYour production has stopped, and you want to get it back in operation – fast. With S2, you have a tool which immediately gives you a graphical overview of what, why and where. Never again you will see your colleagues running in circles in case of a breakdown.
Real reason behind production stopsIn a busy day, the immediate problems are solved so production runs as much as possible. S2 provides you
with a fantastic troubleshooting tool which points out what issues you should solve to improve your uptime.
S2 logs all activities and events which makes it possible for you to search across all these data and find the connection between the data and the stops/faults. This makes it very easy to troubleshoot and search in your historical data. S2 lets you analyze any stops, reasons, and connections between different parameters that creates stops.
Which equipment increases your costs?S2 provides you with an overview of your stops and maintenance time for all your equipment.
Buy an assurance against breakdownsPreventive maintenance is crucial to avoid breakdowns. With S2 you will remember to get the maintenance done – exactly when needed. The status of the maintenance situation will be visible to everyone.
How long time does it take from a breakdown arise until you have found the location and the cause behind it? S2 provides you with a system, which can minimize the time used for breakdown and faults!
1) Locating the breakdown or fault S2 gives you a graphical overview of all your production areas. In case of a breakdown, you will immediately be able to locate the breakdown or fault.
2) Locating the reason behind the breakdown or fault When knowing where to find the fault, it is also important to know the reason behind it. S2 shows you exactly what the cause is, e.g. faults on components, sensors, pushers, network, pulled process stops or pulled emergency stops.
Being able to act on real time production knowledge can ensure that down times are minimized.
Assurance against breakdownsOnline, easy to use maintenance plans are a crucial element to overall effectiveness. S2 offer you this possibility as well. The S2 maintenance module gives you:
▪ Maintenance of your equipment fitted to the exact wear and tear, based on time in operation, number of starts, increased power consumption etc. ▪ Preventive maintenance in due time to prevent
breakdowns
At any given time, you will be able to monitor your current and historical job list for your maintenance. The job list gives an overview of planned, current, completed or deleted jobs.
Altogether, this means that your maintenance crew can be fast and accurate in problem solving and carry out your preventive maintenance – quick and efficiently.
Increase your uptime with S2
S2 connects to your components
S2 is connected to all your components in your production. Thus, S2 is able to display data from these centrally which also makes it possible for you to control the components centrally.
Frontmatec develops world-leading customized solutions for automation in the food industry, other hygiene sensitive industries and the utilities industry. We are especially renowned for our high-quality systems for the entire value chain of the meat industry – from carcass grading, slaughter lines, cutting and deboning lines, hygiene systems and control systems, to logistics and packaging.
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