Premium Deli Meat Processor Reduce Errors and Gains Visibility Integrating Radley’s X/DC with Scales & MES System

Imagine the ability to track lot, part, quantity, temperature, date, serial number, vendor - any data element - all with one single scan…

Gaining the visibility to more information than ever before…

Processing thousands of transactions with only hundreds of scans…

This is what one premium deli meat processor is now able to accomplish after implementing Radley’s X/DC data collection solution in all 5 of their processing facilities.

Before implementing data collection, product classifications were recorded manually on spreadsheets. This process was very cumbersome, and as a result, not all of the necessary data elements that were needed for traceability were being recorded. Product data was only being recorded at the end of the process, leaving them without an accurate view of their Work in Process on the production floor. After implementing their new ERP system, they realized that they would need to process hundreds, if not thousands of data elements per day. All of these factors convinced them that a robust automated data collection was a requirement. A homegrown distribution system and a manufacturing execution system (MES) were already in place, so they looked for a data collection solution provider that could provide seamless integration into these systems simultaneously as well.

Phase I of the implementation began with purchase order processing (Receiving), and Inventory, using bin transfers, warehouse transfers, and issuing and returning of Material to the shop floor using Material Increases and Decreases.

When inventory is received, they scan an industry standard UCC bar code to get the DUNS Number, serial number, part number, lot, temperature, and date. Products received are then weighed on a scale that is integrated with X/DC. They have almost 40 scales on the shop floor that are all integrated to X/DC to process many of their transactions. To reduce labeling errors all scales are linked to label printers and labels are produced at the point of weighing. Since their legacy distribution system is an integral part of their business process and is linked to their financial system, all transactions are validated by X/DC against the distribution system before the ERP system is updated. This validation triggers printing of a label that verifies that the transaction was processed correctly.

Phase II of the implementation involved the integration to their Process Manufacturing module. Automated transactions include Material Issues, Material Returns, Stock Conversions and Job Outputs. Implementing Radley’s IntelliLabel solution eliminated the need for multiple scans. IntelliLabels associate all of their critical information, such as temperature, weight, lot, part, and date all in one scan, reducing the number of physical scans an employee has to complete to obtain all the needed product information. Radley’s IntelliLabel solution also aids in the ability to trace product back through the system.

This premium deli meat manufacturer is now benefiting from the ability to have an immediate and accurate snapshot of their WIP inventory on the shop floor. They have also reduced errors now that all transactions are validated and integrated with their ERP, distribution system, scale equipment and MES. Their greatest benefit has been the increase in their yield from raw material, labor, production and machine time.