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Packing Management

Home / Archives for Software / Packing Management

Traceability enabled in Ireland’s Largest Pig Processor

20th December 2017

Rosderra Irish Meats Group is the largest pork processing company in Ireland. The group processes over 1.5 million pigs per annum across its two state-of-the-art processing facilities at Edenderry, Co. Offaly, and Roscrea, Co. Tipperary. In addition, Rosderra has a speciality Meat Ingredients facility in Clara, Co. Offaly, a Pork-Curing facility in Jamestown, Co. Leitrim, and a Cooked Meats facility in Stradone, Co. Cavan.

Rosderra approached Emydex in 2014 to replace their existing traceability and production control systems operating across the group approaching end-of-life. After winning a competitive tender, Emydex was awarded the contract to supply a new factory floor data capture IT solution that operates door-to-door across the group’s four main operating plants. All production processes were to be covered, including weighbridge integration, lairage, grading, primal deboning, further processing, packing, order picking and dispatch, stock, yield management and traceability reporting.

Split into eight distinct project phases, the project also included implementing Emydex’s Cold Store system into Rosderra’s Cold Store facility in Jamestown and tight integration with third-party warehouse management systems operating in external cold stores utilised by Rosderra’s production plants.

As part of the initial project phases, Emydex worked with Rosderra’s IT integration partner to build robust interfaces to the group’s SAP system. Integration points were built using AS2 and XML transfer files to allow Emydex to pull products, materials, and customer files from SAP, as well as Customer Sales orders destined for both Rosderra production sites and third-party cold stores, and later send updated Stock data back to SAP for stock valuation and available-to-promise purposes.

After completing the roll-out of Emydex’s Packing and Warehouse Management systems to Rosderra’s four operating plants in early 2016, the focus shifted to the Boning Hall operations in Edenderry and Roscrea. These project phases included implementing Emydex’s boning hall systems for cutting, boning, further processing, and Yield Control. Yield Reporting from Emydex includes Carcass chill loss, Cutting yield, chill loss/cutting summary and Boning Hall yield reports.

Presently, the project is in its final phase, which covers the Abattoir operations at both Edenderry and Roscrea, including a centralised slaughter plan and livestock appointments system, weigh-bridge integration, lairage bookings, bulk sequencing, and detained and pig grading stations. Reporting will include a real-time slaughter line monitor program that will accurately display the status of the slaughter with analysis by lot. Slaughter line analysis can be displayed in both tabular and graphical reporting formats.

Commenting on the project, David McMahon, Emydex CEO, said, “We are now well into the final stages of a two-year Emydex systems roll-out across the Rosderra group, covering door-to-door processes as well as integrations to back-office ERP, 3rd party cold stores and suppliers as well as factory floor machinery. Looking back over the two years, I see the project has run smoothly. Both the Emydex and Rosderra project teams worked well together to plan and deliver each project phase on schedule without any major disruption to operations. Rosderra is now reaping the benefits of having a robust factory floor data capture Production control system installed, with Emydex providing group and plant managers and supervisors with real-time and accurate reporting on their Production Yields, Stocks and Traceability.”

Louis Ennis, Rosderra Group Finance and Emydex project sponsor added, “Rosderra Irish Meats Group chose Emydex as an end-to-end solution to replace our legacy system. The installation, which is currently ongoing, will be completed over multiple phases across multiple sites, with all implementations running smoothly and with minimum disruption to the business. The first implementation was the warehouse and packing modules, and, through added interfaces with our ERP system, brought immediate benefit to the business through greater visibility on orders, improved data validation and reduced administration, especially around our cold store loads where manual input has been greatly reduced. Overall, the system greatly improved real-time information and offered ease of use and improved flexibility when making changes”

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Filed Under: Carcass Management, Customer News, ERP Systems Integration, Europe, Industry News, Kill Line & Settlements, Packing Management, Pork, Production Planning, Traceability Reporting, Warehouse Management, Yields & Costings

Rosie & Jim Value Added Poultry Processor live on Emydex

27th September 2017

Dublin – Ireland:
Rosie and Jim was established in 1997 when award winning craft butcher, Jimmy McLoughlin established Quality First Ltd and began producing gourmet chicken products for supply to butcher shops and restaurants. Today the company produces a wide range of premium quality, ready-to-cook gluten free breaded and battered chicken products.  They also produce a variety of delicious filled wraps.  All products are available chilled or frozen.

Order Control

Rosie and Jim approached Emydex in 2016 with a view to implementing a factory-wide Production Control and Traceability Reporting IT system door-to-door. The company had no existing factory floor IT system in place, operating manual processes instead, which meant excessive recording of internal processes manually on paper, which was both laborious and time-consuming, and offered little by way of real-time production control and traceability reporting.

The company had no real insight into the quantity or value of their existing stocks, resulting in procurement planning issues. Unsure of what current stocks were available to fulfil production orders, often resulted in over-ordering of stock, and the holding of excess stock of raw materials, dry goods and ingredients on-site than was needed.

Recipe Formulation

Another issue Rosie and Jim faced from their manual process was knowing how much each production batch cost to produce. Without knowing the precise amount of raw materials and ingredients going into each production batch, and without knowing the exact value of that stock, it was impossible to accurately calculate profit/loss and production yields.

Emydex’s Recipe Formulation Software system means that now, every item is scanned and weighed into a production job in the correct quantities. The system allows Rosie & Jim to track and record every item right down to the smallest measurement that was used in a production job. By doing this, Emydex determines the value of items used in production batches, allowing the system to calculate the cost of each production batch.

Real-Time Traceability Reporting

At Intake, Emydex allocates an internal traceability number (ITN) to each batch of supplier goods received, and the goods are labelled with barcodes and stored. From this point forward, the goods are tracked and traced by factory operators using hand-held scanning terminals, throughout the different stages of production, up to the point of sales order picking and dispatch, This allows for real-time traceability reporting throughout the plant, both for forward trace reporting from suppliers to end-customers, as well as backwards.

Sage Integration

Prior to go-live, Emydex was tightly integrated with Rosie & Jim’s existing Sage 200 accounting system, with Purchase Orders and Sales Orders pulled down from stage, and well as production data sent back to Sage for invoicing of customers and supplier payments.

Go-live

“We started using Emydex on the floor in two separate stages. First, we launched Emydex on our breading line while still using test data. This included the recipe blending and packing. By the end of the first week most of the production team using the system were already comfortable with using it. You could visibly see them speeding up when going through the individual screens.  

We also started to receive goods in from Intake onto the system. This has been simplest of part of the implementation. We soon after went live proper on the 1st of April. We first implemented Emydex on our mixes & tortilla line and began to pick our sales orders via the hand-held scanners. Overall, I feel the project was a successful implementation, and the new system has been well received by our production team, operators and supervisors, better than I could have expected”.

Peter Turner, Financial Controller with Rosie & Jim

Production Reporting

Rosie and Jim now have a comprehensive reporting structure on all aspects of their production processes. The Emydex back-office reporting module provides the company with a number of different views over their cost/value figures including Real-time stock inventory and valuation, Production costing, Production costing variances, Product usage reports, production yield reports and product giveaway reports.

Emydex also worked with Rosie and Jim to develop additional reports such as Production & packing time efficiency reports and daily stock movement reports.

“From a reporting side, by the end of the first week, our production manager and I started to see proper results with regards to yields, packing volumes and stock control. I would like to thank the Emydex team as they really helped, not only with the actual development but also with suggesting practical solutions to suit our processes e.g. line-side management.”

further comments by Peter Turner, Financial Controller with Rosie & Jim

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Filed Under: Customer News, Europe, Further Processing, Industry News, Packing Management, Poultry, Recipe Formulation, Traceability Reporting, Warehouse Management, Yields & Costings

Clogherhead Fishermen’s Co-Op: Labelling at Sea

14th June 2017

Fish Processing – Clogherhead Fishermen’s Co-Op

Clogherhead Fisherman’s Co-Op, is a leading Irish Seafood producer based in Clogherhead, Co. Louth, on the East Coast of Ireland. This video describes how Clogherhead Co-Op use Emydex’s Production Management and Traceability software on their fleet of trawlers as well as throughout their processing factory for data capture, labelling of product at sea, landings, into-warehousing, sales order picking and dispatch, providing Clogherhead Co-Op with real-time and accurate Traceability reporting from boat-to-truck.

Emydex’s Labelling at Sea software operating on the fleet of twelve frozen at sea trawlers, enables on-vessel printing, meaning product arrives to shore already labelled, saving time and ensuring full Traceability from the boat to the customer.

<!–Clogherhead Co-Op Video–>

Fish Processing and Traceability

Processing and Traceablility

Project Highlights

“The key for me is that Emydex were able to provide Clogherhead with their standard fish system built in consultation with BIM (Irish Fisheries Board), the SFPA (Seafood Fisheries Protection Agency), as well as the GS1 (Global Standards agency), but allow Clogherhead to tailor and tweak the system to suit our specific needs and processes exactly.
Aside from our old factory floor system, we also previously operated a bespoke-built boat invoicing and payments system.

Emydex were able to configure and build into their standard Fish system, the very same functionality as our previous system, meaning we now have everything we need in a single system, supported in-life by the Emydex support team. After a year at sea, the Co-op that includes the factory and fleet of boats all see the efficiencies and savings realised from our new labelling-at-sea systems”

Paul Boyd, Managing Director – Clogherhead Co-Op

“This project included a first for Emydex, in that our software is now operating on a fleet of boats in an offline environment, but at the same time has proved very successful. Hopefully over time this is something that will be adopted by the fishing industry as a whole”

David McMahon, Emydex CEO

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Filed Under: Customer News, Europe, Fish & Seafood, Industry News, Packing Management, Traceability Reporting, Warehouse Management, Yields & Costings

Stock Control & Dispatch System live in Wodonga

11th January 2017

VICTORIA – AUSTRALIA:

Established in 1965, Wodonga Abattoir is a leading export-focused multi-species meat processor, based in Northern Victoria, Australia. Wodonga Abattoir processes approximately 45,000 tonnes of meat per annum, including 70,000 cattle, 1,200,000 sheep and lambs, 10,000 Bobby Calves and 300,000 goats. Their products are 100% processed for export markets including USA, Canada, Mexico, Japan, Korea, Russia, South Africa, Indonesia, China, Malaysia and Middle Eastern Countries and hold both Halal and Organic Certifications.

Warehouse Management System & Sales Order Processing

Wodonga approached Emydex in 2016 with a requirement for a flexible Warehouse Management system that would work in tandem with their existing internal IT systems, but would offer them more accurate and faster reporting across the organisation. They needed a system that covered Sales Order Entry as well as Dispatch, that also managed transfers of stock between their main site and external Coldstores, as well as dispatches from the external Coldstores to end customers. They also needed a centralised data repository to consolidate and integrate departmental data and a system that could grow as required with the option to implement additional modules at a later stage.

As Wodonga are an export focused processor, they needed a system that could operate in foreign currencies, that could be linked to a particular vessel leaving Australia for export markets. Finally, they needed a system that could interface with OzDocs, an Australian export documentation system.

OzDocs Export Documentation

As part of the Emydex Product File setup for Wodonga, Emydex configured a new export tab specifically for the meat standard cut codes in Australia, that are used to describe export products. Export data is sent, along with the units and weights, production dates etc. to OzDocs, which is then able to communicate with the regulatory authorities and produce the necessary physical documentation. In Australia, a statutory requirement for exporting goods is the ability to assign port mark stamps to items for export. Emydex’s Australian system is now configured such that assigning Port Mark stamps to box labels is a very quick and easy process, fully audited, and allows Wodonga to decide how they are going to assign Port Marks on each shipment.

Inter-site Transfers

Another feature Emydex added was the ability to scan items (both cartons and carcasses) to a ‘transfer’ order to track it leaving the plant, as well as the ability to re-scan back into stock at the other end. This can be an automatic transfer where goods are ‘auto received’ into sites where there is no integration in place between Emydex and the receiving site’s system, or they can be scanned in at the pallet level to confirm receipt where Integration is in place. As part of this process Wodonga can print an ‘MTC attachment’ which describes the export markets the product can be sent to and reduces the manual paperwork involved in transferring stock.

Inventory Reporting

Emydex provided Wodonga with an advanced Inventory Stock reporting system, providing real-time visibility of stock across the organisation, including reports for 3rd Party Cold Stores, detailing what stocks have been dispatched on their behalf. Wodonga now have automatic stock reconciliations with Cold Stores, significantly reducing the time taken to track and reconcile external stock.

Dual Units of Measure

As part of the inventory management system, Emydex allows Wodonga to view their stock in one unit of measure, such as KG’s for example, but then to price/sell products in a different units of measure such as lbs and pieces (units). “The ability to procure, store, and sell products in different units of measure is an area standard ERP systems really struggle with”, said Ian Carson of Emydex Australia “the fact that Emydex was designed to specially cater for such scenarios is one of the big differentiators between Emydex and other factory floor systems” he added.

Commenting on the project, Rod Scarvell of Wodonga said “Overall there have been some great speed improvements and efficiencies with the introduction of Emydex in Wodonga. The company now has better visibility of inventory stocks across the extended organisation, so the benefits of installing Emydex are immediately obvious”

Due to the nature of the company, Wodonga Sales Orders are typically quite large. Emydex provided Wodonga with functionality that enables the company to break down large sales orders into smaller ‘dispatch’ orders that they can track and invoice, while at the same time retaining links to the larger overall Sales Orders.

Forwards and Backwards Traceability

As with all Emydex systems, full backwards and forwards traceability reporting is included as standard. Wodonga can easily track all movements of stock including movements and dispatches that happen at the External Coldstores. The forward and backwards traceability reporting allows operators to find quickly and easily, what Sales Order a box was dispatched on or vice versa, find what Boxes went out on all Sales Orders.

Emydex System Benefits

Wodonga now have a simple, consistent and clean user interface which has been readily adopted by their users. By using the Emydex in-built report writer, Wodonga’s IT users now have the ability to write their own reports, eliminating the reliance and cost for external technical support. With the removal of the need for a separate ‘reporting’ database, reporting accuracy and speed have been greatly improved.

Commenting on the project, Rod Scarvell, IT Manager with Wodonga Abattoir said “we had been talking to Emydex for almost 3 years before we made the decision to implement their factory floor IT system. The Implementation itself went very smoothly, so much so we decided to change some of our internal work practices along the way to suit the system, ultimately improving the business. The Emydex project manager kept everybody on track and ensured each person got their required jobs done in a timely manner, and their Lead developer and local representatives were very knowledgeable about not only the Emydex product but also how this related to our particular business processes. The main advantages of Emydex we see at this early stage are the company now has better visibility of inventory stocks, coupled with the overall speed of operation, and system running on a modern SQL platform. Post go-live the follow up from the Helpdesk support team for any issues that arise has been excellent.”

For more information on our Beef Processing Software click here

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Filed Under: Australasia, Beef, Customer News, Industry News, Kill Line & Settlements, Packing Management, Traceability Reporting, Warehouse Management

Emydex Live in World’s Largest Ostrich Processor

7th December 2016

OUDTSHOORN – SOUTH AFRICA:

World’s Largest Ostrich Processor

Established in 1985, Klein Karoo is the world’s largest Ostrich processor, producing 65% of all Ostrich related products found on international markets. Klein Karoo represents more than 800 local farmer members, and produces ostrich meat, leather and feathers. Klein Karoo supplies Ostrich (Poultry) meat, including the famous ‘fan fillet’ to the local South African market, as well as to a growing number of export markets including the UK, Denmark and Sweden where Klein Karoo’s pre-grilled Ostrich meat is today available in five of the largest retailers in Europe.

With its head-quarters in the town of Oudtshoorn, located on the garden route in South Africa, the company operates a large number of processing factories in the region including three separate Ostrich Slaughter and deboning plants located in Oudtshoorn, Graaff-Reinet and Swellendam, as well as a number of other processing facilities including value-added processing, pet treat, pre-grill and Biltong processing operations.

Working in conjunction with a South African Industrial Engineering Company (iPlan Global), Klein Karoo invited Emydex to tender in July 2015, for a factory floor software solution to replace their existing production control systems that were deemed to be end-of-life. Klein Karoo sought to adopt a “leapfrog” strategy in the selection of their new software system i.e., a technological solution appropriate for 2016 and beyond. They also requested a centralised enterprise system in order to maintain one “single version of the truth”. Finally, the system they sought needed to be agile and flexible so as to allow for scale and speed to incorporate business change such as acquisitions.

Kill Line Software Live in Three Plants

Following a thorough tender process, including a project discovery and scoping exercise in South Africa, Emydex were awarded the Klein Karoo contract in January 2016. A team of Emydex developers working remotely from Dublin in close collaboration with Klein Karoo in South Africa, commissioned and configured Emydex software systems for Klein Karoo’s three Abattoir operations, boning halls and value added operations for both Local and Export Markets. A team of Emydex Senior software engineers implemented Emydex systems into the groups three plants over the Summer months of 2016, such that by the end of August all Emydex systems were live and in operation across all processing plants, without any major issues. In tandem, Emydex integrated with Klein Karoo’s new back-office ERP system, Syspro, that was implemented in parallel by iPlan Global.

Commenting on the system go-lives Karoo’s project manager said “The operators at both Graaff-Reinet and Swellendam had a positive experience with Emydex following go-live, and the general consensus is that Emydex seems much simpler and faster to use than their current system. Also taking into account the fact that the users at Swellendam saw the screens for the first time on the morning of go-live, and had no major issues transacting. So overall a positive experience from an end-user’s perspective. The Emydex developers were very helpful during their visit and didn’t shy away from finding on-site solutions or the long hours.”

Full Traceability Reporting

Commenting on the perceived benefits for the business following the system go-live, Cobus Pretorius, Production & logistics Co-Ordinator with Klein Karoo said “The Emydex program interface is really user friendly, and makes navigating through the system very easy, and also the filtering option on all Emydex client screens, make lookups quick and easy. The suite of full traceability reports are easy to navigate, and will save us a lot of time. In addition, the fact that all information and reporting can be extracted to Excel also has a lot of benefits for our business.” Commented Pretorius

He went on to add “from a Warehousing perspective the full scanning throughout the Emydex system is a big step forward for our company, we can already see the huge benefits this gives us in terms of proper stock control. Also by fully integrating with our new financial system, Emydex has eliminated all the work that we had to manually duplicate before. Naturally the human error with regards to these manual duplicated transactions has also been removed.

The automatic integration between our Graaff Reinet & Swellendam plants in terms of carcass shipments to our primary processing facility in Oudtshoorn has also saved us a lot of time and trouble. Lastly, the way labels are set up, and the ability we have to change them with little or no input from Emydex, as well as the fact that we can preview the labels before we have to actually print, is something that I rate as one of my top three system improvements!”

Recipe Formulation Software

“Finally, the Emydex Recipe system, which is something new to Klein Karoo, works really well and we can see that it actually gives the factory workers a sense of pride in actually “measuring” what they are doing and not just blindly mixing bathes. This also ensures that the correct products are used in the correct quantities for all the recipes. The last benefit I would add is that having the ability to be able to trouble-shoot quickly by being able to connect to the actual floor pc’s have made life much easier!” added Cobus Pretorius.

Reflecting on the project’s success, Charl du Plessis, Managing Director of Klein Karoo International said “to incorporate Emydex slaughter, de-boning and recipe functionality into a single business entity in such a short time-frame was great achievement in my opinion”. David McMahon, Emydex CEO added “the Klein Karoo project was definitely one of the most ambitious and potentially challenging projects we have ever had to tackle. The fact that the go-lives went so smoothly, over the various project phases coming in quick succession over the Summer, is down to the hard work and many months of preparation and testing invested by Klein Karoo, iPlan and Emydex working in partnership as a unified team”.

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Filed Under: Africa, Carcass Management, Customer News, ERP Systems Integration, Further Processing, Industry News, Kill Line & Settlements, Markets, Other Processing, Packing Management, Poultry, Recipe Formulation, Traceability Reporting, Warehouse Management, Yields & Costings

Beef Processing Software Live in MeatCo Namibia

5th November 2016

WINDHOEK – NAMIBIA:

The Emydex implementation team returned to Ireland after the latest phase of Emydex system deployments at MeatCo’s two main production sites located in Windhoek and Okahandja, Namibia. At this stage Emydex’s factory floor data capture and production reporting software is now operational from factory door-to-door in both of MeatCo’s main beef primal processing plants, from Kill line through to boning hall processing & packing, sales order picking & dispatch.

In addition to their main primal processing plants, Emydex is now also installed in two further processing plants on the MeatCo Windhoek site that are the Wholesale and Cannery processing plants. Current plans are for MeatCo’s IT staff to themselves complete the Emydex systems roll-out to its other two beef processing plants located North of the veterinary fence in Oshikati and Katima Mulilo. Both deployments will be supported remotely by Emydex’s Implementation team of developers based in Emydex’s HQ in Dublin, Ireland.
At this point there are just under 100 Emydex data capture devices (consisting of PC terminals and hand-held scanners) installed across MeatCo’s four plants operational with Emydex, that include a number of Animal Health and Quality Assurance inspection stations on both Kill line systems, as well as Industrial PC stations covering Dentition, Grading, Primal labelling, Carton Packing, VET Seals, Recipe formulation and Dry Goods stock management.

The Emydex system in MeatCo also provides functionality for 3rd party carcass intake, carcass splitting as well as dispatch. The system is fully integrated to MeatCo’s group wide-ERP system (Sage X3), and has interfaces built to a number of 3rd party Cold Stores in both Africa and Europe.

Having tested and implemented the Emydex kill line & payments system in the Okahandja plant, the same kill line system was later installed in Windhoek over a weekend, going live the following Monday. A fast paced install. “The MeatCo kill line is unique compared to our European kill line systems”, said Emydex CEO David McMahon, “Grading is carried out over two separate stations for example, one per side, allowing different destinations to be associated with each side of an animal, allowing for condemnation or part condemnation of only one side of an animal.”

Commenting on the completion of this main phase of the Emydex project that took just over 12 months to complete, McMahon said “MeatCo have been the ideal customer for Emydex to work with. Highly professional and organised with regard to working with our development and implementation teams on the planning, testing, training and go-live phases of the project. The project ran smoothly over the past 12 months, and we’re delighted to hear now that MeatCo feel they have the sufficient knowledge, in-house capabilities and confidence to continue themselves with completion of our system roll-out to their two remaining processing plants. Our support team will be on-hand to support them 24/7 should it be required.”

Nico Weck, MeatCo’s Group Chief Financial Officer said “Now that the Emydex installation is complete in both our main processing operations, we have a robust Traceability control and reporting system in place that provides our management team with real-time feedback on our production processes. The flexibility that is inherent within Emydex means we can quickly and easily add additional reporting as it is required by the business. ”
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Filed Under: Africa, Beef, Carcass Management, Customer News, ERP Systems Integration, Further Processing, Industry News, Kill Line & Settlements, Meat, Packing Management, Quality Management, Traceability Reporting, Warehouse Management, Yields & Costings

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