Prepared by:

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Traceability, Processing Dispatching Management
System

• Prepared by
• Rimantas Endriukaitis
• IT project manager
• PRALO UAB

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Positioning

• MeatMaster is a manufacturing and warehouse
  management system for meat processing factory
• MeatMaster enables effective manufacturing
  process management by fast data acquisition and
  fast data transfer to company accounting system
  (ERP)
• MeatMaster is a shop-floor front-end system

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Techniques Employed

• Manufacturing Execution System (MES)
• Automated Data Capture (ADC)
• Mobile Data Capture (MDC)
• Computer Integrated Manufacturing (CIM)
• Management Information System (MIS)
• Track and Trace System

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Manufacturing Execution System (MES)

• Production orders are delivered from planning to
  the shop floor workplace
• Control of production flow exactly what, exactly
  how much, exactly from where, exactly to where.
• Helps to make the job the right way

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Automated Data Capture (ADC)

• System captures the data directly from
  measurement devices where it is possible
• System captures data in timely manner data is
  available right after operation is finished
• Write on paper and key in data later is avoided

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Mobile Data Capture (MDC)

• Mobile devices are used to capture the
  measurements
• Workers are not bind to their workplaces with
  wiring
• Operation may be performed where it is more
  convenient to perform it

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Computer Integrated Manufacturing (CIM)

• Operator workflows are controlled by computers
• Computers provide the information necessary to
  perform the operation
• Data on operation results is available right
  after the operation is completed

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Management Information System (MIS)

• Provides information to management to make right
  decissions
• Information is available on-demand, not at the
  end of the month or quarter or year

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Track and Trace System

• Analyze the information on origin of raw
  materials
• Analyze the information raw materials used in
  semi-manufacturers and final products
• Analyze the information on product distribution
  to customers

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Shop Floor Functionality

• Live stock reception
• Slaughtering
• Veterinary control
• Carcass Grading
• Preparation to stock
• Reception to cutting and de-boning
• Quality meat scaling
• Labeling
• Gathering (Picking)

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Slaughterhouse. Challenges

• Calculate carcass price based on meat grading
  results
• Print reception documents
• Keep track on animals on production line
• Keep track on actual frosting and de-boning losses

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Functionality. Slaughterhouse

• Receptionist enters information on supplier and
  his animals
• Butcher confirms animal death by scanning ear tag
  barcode
• Assessor enters assessment data
• Carcasses are scaled before stock
• Carcasses are scaled when taken from stock to
  cutting
• Quality meat is scaled after cutting

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Reports

• Live stock purchase and reception reports
• Grading reports
• Slaughtering reports acording to EU Legislation

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Animal reception. Supplier
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Animal reception. Document
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Animal reception. Animal list
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Slaughtering
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Carcass Grading
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Preparation for Storage
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Reception to Cutting and de-boning
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Quality Meat Scaling
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Logistics. Challenges

• Print correct shelf price
• Label correct ammount of product
• Print correct product information
• Print correct invoice
• Label earlier departuring orders ealier
• Label and gather products on time

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Functionality. Labeling

• Order lines are showed to operator. Operator
  select order line, adjusts additional parameters
  (such as tare types, counties or origin etc.).
  After each scaling a pack label with weight and
  price is printed. System controls when it is
  enough labeled. System prints box label
• Different labeling scenarios for fixed weight,
  variable weight products, box scaling, carcass
  scaling
• Label information translations
• Customer and product specific label layout

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Functionality. Order Gathering

• User scans box label barcodes. System checks if
  all labeled products are scanned for the
  customer, for the route. The user enters amount
  of boxes at the end of order.

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Reports

• Order sheet
• Order lines summary
• Unlabeled orders summary
• Freezing shrink summary
• Productivity analysis report
• Detailed productivity analysis report
• Delays report
• Cattle carcass declaration

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Labelig
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System set-up tools

• Data Editors
• Report designer
• Label designer

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Data Editors

• Product editor names, ingredients, translations,
  tare capacities, storage conditions.
• Barcode editor different barcode structure rules
  for different products and customers.
• Labeling policy editor print pack labels or not,
  print box labels or not, ask for piece count or
  not, and even more parameters
• Tare editor names and groups
• Recipe editor assign ingredients to recipes,
  define output, recipe versioning
• Warehouses and warehouse groups

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Data Editors (continued)

• User and worker groups
• Workplace parameters editor
• Valid batches editor

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Report Designer

• Customize existing reports to meet specific needs
• Scripting inside reports

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Label Designer

• WYSIWYG label designer
• Business logic specific fields
• Text, bitmap and vector graphic fields
• Printer model independent

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Integration Points ERP

• Suppliers import
• Livestock reception data import and export
• Grading data export
• Preparation for storage data export
• Reception to cutting data export
• Order import from ERP
• Labeling information export to ERP
• Picking information export to ERP

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Economical effect for our customers

• 75 less complains from customers after
  MeatMaster installation. 5 complains instead 20
  per week. Penalty for one complaint is 1000 LTL.
  Remaining complaints are related to order
  reception mistakes, truck delays, etc.
• Labeling from 900 to 600 (21 hour long) before
  MeatMaster. Labeling from 1200 to 2400 (12 hour
  long) after MeatMaster installation.
• Decrease from 2 minutes to one minute for one
  order line labeling.

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Customer References

• Agaras www.agaras.lt (Lithuania)
• Agrovet www.agrovet.lt (Lithuania)
• Biovela www.biovela.lt (Lithuania)
• Filee www.filee.ee (Estonia)
• Kaiiadoriu pauktynas www.kaispauk.lt
  (Lithuania)
• Krekenavos agrofirma www.krekenavos.lt
  (Lithuania)
• Oskar www.oskar.ee (Estonia)
• Vilke www.vilke.lt (Lithuania)
• Vilniaus pauktynas www.paukstynas.lt
  (Lithuania)
• Utenos Mesa www.utenosmesa.lt (Lithuania)
• Slaughterhouse module all Lithuanian companies
  slaughtering more than 100 pigs per week
  (http//www.vic.lt/ris/index.php?id6299actionmo
  re)

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Software Architecture

• Three-tier architecture for flexible
  computational resource distribution
• Modular structure
• Firebird DBMS

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User interface

• Shop-floor functionality user interfaces are
  ready to be used with touchscreen large screen
  elements, on-screen keyboards where input is
  needed
• User interfaces may be translated to foreign
  languages without rebuilding the system (default
  language - english)

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System Requirements

• Server 1 GB RAM, 2 GHz CPU.
• Workplace - 256 MB RAM, 1 GHz CPU, 800x600 pixels
  screen resolution, TouchScreen.

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Supported Hardware

• Digi DPS/DI/HI/FX/AW-3600 printer scales and
  wrappers
• SFK Technology FatoMeater
• Scales Digi, AveryBerkel, MettlerToledo, Bizerba
• Zebra printers Z4M, S4M
• CPG printers 6404
• Markpoint printers M104
• Datalogic mobile computers Kyman .NET, Viper
  .NET
• Industrial PCs Digi DS-760, Beckhoff, Forsis

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What we will see in demo

• Receive the animal
• Slaughter it
• Grade the carcass
• Receive it to stock
• Get it from stock to cutting
• Scale quality meat
• Label products