Dashboard data feeds growth at Faccenda

Faccenda Foods is pioneering a new SI production management system, using real-time production dashboards on each of its 15 processing lines.

Faccenda Foods supplies a varied product range to both retail and food service customers across the UK – often with same day delivery.

At its 100,000²ft poultry processing facility in Telford, SI’s software delivers real-time data to improve and inform its operations.

Easy access to real-time information on the shop-floor

“Our teams are much more engaged now that we display information such as target weights for fixed weight products, scheduled processing times and giveaways against our defined targets on dashboards.”

With  real-time production dashboards incorporated on each of its processing lines, the business has already realised the benefits and positive impact of sharing data in an easy to understand format. As David McCarthy, Faccenda’s Production Systems Manager explains: “When there is easy access to real time information, colleagues can make in-line decisions which deliver a positive performance difference to the operation.

Each line is now aware of how well they are doing and any anomalies that are occurring.

“From the moment we displayed information such as target weights for fixed weight products, scheduled processing times and giveaways against our defined targets on dashboards, our teams have been much more engaged.

“Each line is now aware of how well they are doing and any anomalies that are occurring. Friendly competition has emerged as one line aims to perform better than the other. As a by-product, staff share more knowledge and information and are more likely to proactively suggest changes to improve performance.”

David continued, “This has had a positive impact on teamwork and helped us to achieve a much greater visibility of our performance through the processes undertaken to deliver a finished customer ready product. We use the real-time production information on yield, giveaway and productivity to drive the agenda and actions in our Short Interval Control, (SIC), shop floor meetings.

“Now, at our Short Interval Control, (SIC) shop floor meetings, the agenda and actions are all driven by the information on yield, giveaway and productivity provided by the real-time production dashboards.”

100% labelling design and integrity across all lines

“SI also manages our range of Weigh Price labellers and Outer Case (OCM) labelling systems. We do this centrally through our planning and scheduling team. By doing so we have delivered 100% consistency in label design and integrity across all 15 production lines. Date and batch coding are governed by the system negating the necessity of operator input and reducing our risk to human error. Over and under production of individual SKUs is therefore managed, reducing processing waste.

“As a result, our operation is not only more efficient but also our customers are provided with greater reliability, which is recognised as a key strength in our relationship with them.”

“We are now looking at how we can use SI in our “Ready to Cook” operation. As well as the standard systems we have at Telford managing operating parameters, batch and date coding through scheduling, we are developing a stock management system for pre batching ingredients for production assembly runs.

VIEW OUR VIDEO: Automated traceability will eliminate 1.8 tonnes of paper at Faccenda

“This in turn will give us 100% traceability through electronic data archiving, without the requirement for paperwork. We will also use the system to drive ingredient and packaging ordering direct with suppliers ensuring stock is maintained at optimum levels. In “Ready to Cook” we will continue the roll out with our paperless QA solution, which we have implemented at Telford, where all checks are performed on connected devices and information is archived automatically.”

As Rob Stephens, Managing Director of SI explained: “To date we have integrated the labelling, quality assurance, weighing and various WMS systems used to transfer stock records for Faccenda Foods. Moving forward, we are now looking at how we can help the Faccenda team integrate other areas of the business, including its stock tracking system.

Ensuring project success with a modular and systematic approach

“The main advantage of Faccenda Foods taking a modular approach to implementing our solutions, is that we have been able to train staff and embed each new module in a systematic way, ensuring it works, before moving onto the next phase.

“This has had clear benefits and delivered a great deal of confidence to staff that have never used such systems before and with the dashboard, there have been some unexpected, but very welcome additional benefits.”