Hot Sauce Batching MES Application
A food products manufacturer needed to replace an outdated control system for
the preparation of it's hot sauce products.
The outdated system provided limited data collection for analysis of performance.
In addition, the manufacturer hopes to create a plant-wide Manufacturing Execution
System for integrate with it’s existing ERP application. With increasing demands
for lot genealogy and record audit trails for government requirements, the
opportunity was to create an automated batching system which could later be expanded
to include all manufacturing areas, including inventory control, packaging and
quality assurance testing.
When a leading systems integrator was selected to update the control system, they
decided to partner with Pyramid Software to provide the MES piece to the puzzle.
A system was designed to build batch formulas using a library of operation codes
specific to each type of device used at the facility. In addition, an MES modeling
component was designed and implemented to provide rules about the layout of the
facilities components and product routing.
The MES model and it's transactions were implemented using COM component technologies
so that the HMI developed by the systems integrator has scriptable access to the MES
The system is collecting area performance data such as batch efficiency and
equipment utilization. A series of reports is used to present management with
historical performance information linked by area, product and operator.
The first phase of the system has been implemented and an immediate benefit has
been a potential reduction of cycle times by several minutes per batch.
Management is now able to analyze the data being collected in order to establish
and maintain a continual process improvement program at the facility.
Plans are to expand the current system into the other manufacturing areas.