Our food processing OCMs manage more than just labels.
Based on the yield, SI's OCMs also manage the calculations to ensure batches are correctly changed. Whether you need to track by delivery or relatively small batches, the OCM monitors the batch prevents automatic overbooking and booking against the wrong production run. If a better yield has been achieved, a manual override can be made and recorded.
With these checks and balances in place, booking to production will always be done right the first time and, for auditing, traceability data will be both robust and accurate.
"The software managed date and batch coding, negating the need for operator input and reducing risk of human error. It also controls over and under production of individual SKUs to reduce processing waste." Faccenda Foods
To find out more about SI's OCMs, OCM software, and our wide range of food processing software:
Across our range of weigh price labellers and OCM (outer case markers) labelling systems, SI delivers 100% consistency in label design and integrity across all 15 production lines.
David McCarthy, Production Manager, Avara Foods
To find out more about SI’s OCM and labelling software and how it improves food manufacturing efficiencies, simply complete the form and we’ll get right back to you.
For food processors, reactive rather than proactive planning is the norm. As customers' requirements are constantly changing, invariably, the retail forecast doesn't match the order reality. This means that no two days present the same end requirement for production. That’s why SI developed Available to Sell.
Available to Sell shows a real-time view of stock levels, based on raw material and orders received. The moment your production plan changes or a new order is received, Available to Sell is automatically updated.
To find out more about SI’s Available to Sell and Plan to Produce software and how it could improve food manufacturing sales forecasting within your business, simply complete the form and we’ll get right back to you.
By combining this information in real-time and understanding the impact of seasonal spikes, key events like sporting fixtures or school holidays, production forecasting can be refined over time to create a more accurate planning tool.
This provides operations teams the foresight they need to ensure the right staffing levels, in addition to improving relationships with the supply chain, who benefit from more accurate order volumes.
Being flexible enough to change in real-time also means producers have time to ensure the ‘golden rule’ of order fulfilment is achieved, even if additional stock needs to be purchased outside of the business.
A production plan can be a mix of production forecast, sales forecast and sales (actual sales will replace the forecast).
Effective forecasting means that buyers are able to make informed purchases several weeks before customer orders are finalised. They can then negotiate the best price for raw materials.
Similarly, operations staff are able to achieve most efficient use of resources, minimise waste & ensure orders are met on time.
Production forecasting that supports both short and long-term planning
For food processing sectors like fish production and catering butchers, production forecasting can support better planning, pushing out to three to four weeks. Similarly, with cheese production, forecasting can be pushed out for years, to cope with the length of maturation needed in this industry.
With SI, now food processors can produce a forecast as far in advance as required. For instance, cheese producers may want a forecast for up to two years in advance, but in the case of more perishable goods, a matter of weeks will be sufficient.
The trouble with food production forecasting
The trouble with standard forecasting is that predictions will always be inaccurate if the data provided isn’t reliable, and it's difficult to take into account the impact of short product life and last-minute order changes. Production and sales demand can only be met if the food processor has sufficient raw materials, packaging and labour resources, and can predict upcoming orders.
The knock-on effects of inaccurate forecasting results in problems with raw material stock and inability to meet sales orders. For some food processors, overstock will involve having to freeze any surplus. Whereas insufficient raw material forces last-minute stock purchases and the potential to miss customer delivery deadlines.
To find out more about SI’s food production sales and production forecasting software, simply complete the form and we’ll get right back to you.
Whether you need to track by delivery or relatively small batches, our OCMs and software monitor every batch to:
Tracks balances for what's been issued (using a trace ID);
Prevents automatic overbooking and booking against incorrect production runs;
Manages calculations, based on the yield, to ensure batches are correctly changed.
Eliminates mistakes by ensuring that products can only be booked to output if details are correct.
To find out more about SI’s fish and seafood traceability software and how it could improve efficiencies within your operations, simply complete the form and we’ll get right back to you.
SI developed Runmaster, as part of the Integreater software suite, to cope with the complex challenges that are an everyday norm in the food processing industry. Managing perishable raw materials, dealing with overstock that will quickly go out of date go out of date, or alerting production teams when too little stock is available to fulfil orders. Integreater even automatically logs machine breakdowns.
By allowing users to plan daily production in seconds, including labour, raw materials and packaging requirements, Integreater quickly provides our customers with a full and accurate view of each day. By having a solution that gives you “one version of the truth” automatically calculating what needs to be produced, and by accounting for the finished goods that are already on site, there is no need to manually calculate raw material or packaging requirements. Our food production planning software also takes into account which lines each product can be produced on, vehicle departure times and any planned breaks.
View our video to find out more about how Runmaster could simplify your daily planning.
Automate your crewing plan
Planners can set staffing levels against jobs and lines and it will automatically calculate the total operatives required across production. Managers can also set planned breaks, wash downs, scheduled maintenance and changeovers.
Our production planning software also accounts for the scheduled departure times of depot delivery vehicles. It identifies if the current production plan will meet these important deadlines. This is live, so the effects of any delays are immediately visible. If necessary, planners can easily split production runs between lines so that orders can be despatched on time.
With Integreater, the complex planning process is automated and a daily plan can be produced in under a minute. Planners are able to make updates easily and instantly to see the knock-on effects that any changes will have. The software is also clever enough to suggest corrective action.
Runmaster will give you a live view of your plan, as well as production progress.
It will enable you to log any last minute changes or issues in seconds and will immediately calculate the knock-on effects they will have on production time, as well as raw material and packaging requirements.
Your complete daily plan will be visible on one screen; with Runmaster, drill-down to the fine detail for products, orders or customer-specific information in seconds.
How Runmaster could simply and automate your daily plan:
Create and distribute a daily plan
Calculate crew levels
Create and distribute a raw material requirement list
Create and distribute a packaging requirement list
Add breaks for wash-downs, power-downs etc
Update the plan with changes and top-up orders
Adjust the plan to account for problems, such as machine breakdowns
Move orders/products onto different lines
Republish the updated plan
With Runmaster, you will be able to complete any of the above actions in seconds.
To find out more about SI’s food production planning software, simply complete the form and we’ll get right back to you.
Within SI's Cost Modelling module, Bill of Materials Software maps out all product relationships for both reduction specifications and combination specifications. Bill of Materials details raw material conversions to work in progress (WIP) and finished goods products.
One of the main problems encountered with recipe-based production relates to reconciling batches and ingredients stock levels. For complex recipe-based food processors, having a detailed understanding of product demand helps to ensure that the right Bill of Materials (BOM) is available.
Bill of Materials recipe make up
"By using SI's software to validate recipe make up, we ensure that the right ingredients, at the right quantities, are issued to manufacture products."
Finnebrogue Artisan
Cost modelling maps out standard conversion costs of raw materials into finished good products including target profit margins. Then, detailed levels of variance analysis can be shown, comparing shop floor information with standard cost models.
With standard costs set up within Cost Modelling, the bill of materials is mapped out to drive works order processing, production planning, and more.
Then, SI’s stock control system combines data on raw material, allocates stock for individual recipes, controls work in progress (WIP) and the despatch of finished products.
By the automation of product allocation, with ingredients weighed and measured to controlled tolerances, it simultaneously updates the bill of materials in real-time. Then, as stock is consumed, it prevents any unwanted products from being used within a recipe.
DOWNLOADour Integreater QA Application Suite Brochure
To find out more about SI’s Cost Modelling, Bill of Materials and Recipe Management software, simply complete the form and we’ll get right back to you.
SI’s Despatch Tracker provides a real-time view of progress for despatching and picking against sales orders, within the food factory’s picking and despatch area.
Despatch Tracker and Loads Out is a desktop application, that’s used by food manufacturers to review all orders that need to be picked and that can then be grouped or tied together for a load.
To find out more about how SI’s order and picking software will minimise errors within your despatch area, simply complete the form and we’ll get right back to you.
Every sheep has a unique RFID tag. This tag is scanned before to the sheep is killed and provide information on where and when the sheep/flocks have been moved, and categorically link back to the farmers. Using this information, we can provide farmers with the reassurance that they will get paid for precisely what they sold.
For more info about SI’s livestock payments and adjustments application, simply complete these details and we’ll get right back to you.
To find out more about SI’s Kill Scheduling Application and how it could improve efficiencies within your abattoir, simply complete the form and we’ll get right back to you.
As QA data is captured, tracked and any issues are flagged up, our application:
Shows how many checks are being performed, when they are happening and identifies any non-conformances.
Evidences that operators have carried out the correct checks and at the prescribed time intervals, by scanning at critical control points (CCPs) throughout your food factory.
Puts stock on hold at any food manufacturing stage, for follow up QA checks.
Controls quarantined items, to prevent cross-contamination and manage any rejects.
Minimises non-compliances, for both customer and regulatory standards, through digital validation and safeguarding.
And by using our Hygiene Application, controls all food factory cleaning and hygiene routines.
SI's QA application can either be operated as a standalone module or integrated within our own food ERP solution. Then, captured QA data can either be synchronised to transfer in real-time, for analysis, or, when working offline, uploaded once devices reconnected to the network.
Minimise administration time
With instant data retrieval, Digital QA has the potential, for large enterprises, to eliminate thousands of man-hours spent on administration. And with more time available to spend on QA review and analysis, managers can explore the new levels of digital reporting provided by SI’s QA and traceability software.
For example, review digital QA procedures by product code to analyse:
How many finished products resulted in non-conformances and why?
Were the non-conformances the result of issues with packaging specifications, recipes, raw materials, or something else?
By understanding, the issues and patterns, what evidenced-based changes should be applied and measured?
QA digitalisation that's proven to deliver cost savings
For any food manufacturing business, minimising waste is a priority. But with our QA module, once any non-conformances or issues are identified, such as variable raw material quality at intake, problems can be quickly addressed and rectified.
And, by moving away from paper-based QA, one of the hidden cost benefits is the saving that's made against paper and ink spend. For a large enterprise, this saving can equate to several £0000s.
For Avara Foods, we've been able to quantify this saving. At its Telford plant alone, digital QA of technical processes has eliminated 1.8 tonnes of paper per annum.
The Integreater QA system would provide the following; Turn all manual paperwork checks to electronic that can be captured on a handheld device (tablets, scanners, etc.) Real-time visibility of checks on the shop floor through real-time trackers and reporting Ability to capture photographic evidence that can be held against the results of the check Reporting and analysis – immediate retrieval of QA information for audits Non-conformance management built in – auto alert QA supervisors/management of non-conformances Alerts on handheld to operators for hourly checks CCP barcoding – scan CCP (i.e. metal detector) to prove that the check was done in the right area Integration with check weighing equipment and blue tooth thermometers Checks against product specifications. Retail label verification (off line) can also be incorporated This can also be fully utilised by engineering department for line checks, downtime, consumption of parts/tools, etc. SI also has a lab sampling application for batch samples and lab test result logging.
Of course, when the data is manually collected, the chances are that the level of detail about individual animals, lots and farms will be scant.
It also means that other issues, such as livestock arriving dirty, is far less likely to be documented. Without evidence, the cost of cleaning cannot be charged back to the farmer.
Vet data, traced right back to the farmer
As SI's Veterinary Data Management application (also known as the Vet Screen), captures kill line data, the required health checks, any exceptions or conditions (such as injuries or health issues). The abattoir vet screen also records traceability data, by tracking each animal record back to the original farm or lot.
With SI's veterinary data application, if offal is condemned, it's recorded on the screen against the animal and lot. Thanks to the data capture, animals can be tracked right back to the farmer and, as well as negotiating a better price for his animals because of the welfare problem.
Good use of post-mortem data can lead to better returns by improving productivity. It can also minimise the losses of saleable meat and offal & shows the abattoir who their best farmer producers.
“As we share information with our farmers, SI developed an inclusive animal by animal report, including grade and veterinary details. The feedback we’ve received from farmers has been brilliant; many have commented about how much the information has helped them to improve herd health.”
Hayley Draper, Lairage Manager, Pickstock
“With SI, we're 100% sure that MHS health data is accurately attributed to the correct animal and animal batch.
Our producers use the reports to benchmark performance of healthy animals v. animals that had any health issues.”
“I can see my entire plan on one screen and have complete visibility of Forecast, Pre and Final orders. It's easy to make changes, add orders, move products on to different lines, insert breaks, add forward production or adjustments. I can also click on any item for detailed associated data such as which stores’ orders contribute to a product’s production figure. Integreater automatically calculates and instantly displays any knock-on effects.”
Kerry Castillo, Scheduler, Vantage Foods.
To find out more about SI’s food manufacturing production scheduling software and how it could improve planning within your food processing business, simply complete the form and we’ll get right back to you.
For bakeries and cake manufacturers, these are some of the many challenges that SI's know-how and recipe management software is resolving:
Regular problems with incorrect quantities, weights and raw materials being issued to the recipe mix.
Too much is lost through giveaway, wastage, quality issues and product recalls.
Poor management of raw material stock and labour costs detrimentally impact profit margins.
Inability to keep track of raw material batch consumption and stock.
Inefficient stock control and rotation.
Manual scheduling becomes too complicated to manage, as product ranges and formats expand.
Inability to control multiple processes and manufacturing stages, especially recipe formulation and mixing, WIP, racking cooking, cooling and finishing.
SI's recipe management software maps out combination specifications and manages every bakery production process, including scanning to batches, mixing, make-up, baking, cooking and cooling, and even slicing.
Full ingredient traceability and control
SI's recipe control software tracks and manages every detail of the recipe batch, including:
Any instructions for finishing touches
Partially completed mixes.
Tolerances for each item to be issued to the recipe mix
Controls temperatures where an over-tolerance will result in burnt products and poor yield.
By using our cost modelling software, bakeries and cake manufacturers can map out costs for all ingredients and product relationships. And whenever prices change, SI's cost modelling software automatically adjusts all relationships as well as the costs.
Waiting for specific raw material that's out of stock for your recipe?
With SI's recipe control software, part completed mixes can be booked back into stock and reintroduced to finish the recipe mix, once outstanding raw material is available.
Bakery & Cake Manufacturing information
As your bakery or cake manufacturing business grows, so do your challenges. And, where there are any inefficiencies, these are magnified.
Complex supply chain management
Multiple raw material formats and intake management
Silo and stock management
Complete recipe control
All of these are critical processes for bakeries and cake manufacturing operations.
To find our more about SI’s recipe management software or request our bakery and cake sector brochure, simply complete the form and we’ll get right back to you.
To find out more about SI’s auto-spec ID application and how it could improve efficiencies within your abattoir business, simply complete the form and we’ll get right back to you.
Looking for the best Food ERP system? SI has been dedicated to developing solutions for the food manufacturing sector for almost three decades, our approach has always been different. Through the combination of our modular food ERP and real-time planning software applications, driven by our renowned, fully-integrated shop floor data capture, our transformative solutions are built to fit the food manufacturing industry.
The one size-fits-all ERP solution hasn't ever been the panacea to resolving complex food manufacturing process improvements and gaps. Invariably, this approach leads to a plethora of work-around solutions.
And with SI, we add our expert knowledge of food production and reporting to give you data driven insights, that are proven to deliver performance improvements across business operations.
The result? “One version of the truth” from every interaction, every process, every ingredient and operation, delivering digital operational control from supply chain right through to the customer. Looking for the best food ERP? SI will enable your food manufacturing business to be more collaborative, efficient, profitable and responsive.
Click on the panels below to explore our range of food ERP applications.
Simplify and digitise livestock procurement processes with SI's Livestock Bookings and Scheduling applications.
Many of our meat industry customers that have stepped up to SI's digital livestock bookings and scheduling system to eliminate onerous paperwork and repetitive manual spreadsheet inputs.
Their businesses are now reaping the benefits of the system, with livestock bookings that can be made up to six months in advance, to account for predicted calving times.
From the moment livestock becomes available for purchase - whether it's weeks or months in advance - using our livestock bookings and scheduling software:
Confirm livestock bookings, as far in advance as required.
Record all animals, quantities, supplier, and livestock arrival details.
Review and segment data, such as how many animals will be received each day.
With a real-time view of the booking diary, buyers can chase or defer livestock deliveries for specific days.
Create lots and assign livestock arrival time slots at the abattoir, for farmers and producers.
Manage bookings across multi-site operations and gain a real-time view of the booking diary.
The application can even assign supplier/producer codes and detail transport leadtimes.
And for an instant way to organise livestock bookings into time slots, SI's Livestock Bookings and Scheduling application's diary view feature:
Manages sequential slaughter time slots.
Can allocate more than one booking to the same time slot.
Provides lot numbers, animal quantities, supplier/producer codes, supplier/producer names, and first line of address.
To find out more about SI’s Livestock Bookings and Scheduling Application and how it could improve efficiencies within your abattoir business, simply complete the form and we’ll get right back to you.
Download our Abattoir and Meat processing brochure here
Delivering a quality experience to consumers, therefore requires flexibility, speed and control of production lines. Some of which can involve multiple processes and ingredients, all mixed together to meet defined tolerances.
From baton carrots to fresh spicy salads
At SI, we work in partnership with processors to integrate their production lines, controlled by real-time shop-floor data capture and on demand reporting.
It all starts with stock control and production planning, to ensure the right raw materials and packaging products are available. With simple single packed products like baton carrots, this includes measurement and control of washing and grading processes.
But for more complex recipe-based products, we have designed specific recipe management modules that control the mix of each batch to pre-defined tolerances. From the issuing of raw materials to the control of the mixing and/or cooking processes, our software not only gets the recipe right, but it also measures and reports on the processes themselves, confirming everything from mixing times to cooking temperatures.
Managing the stock of ingredients in real-time, the operations team can see and manage stock levels from one central hub. This allows ordering additional stock as and when required.
Take control of part completed WIP mixes
Missing a key component of a recipe previously meant that producers had to stop their processes. With SI, once you start you can stop part way through a WIP mix and issue this back into stock. As our specialist recipe software module has capability to trace quantities of raw materials within a batch and mix at any stage.
This allows producers making complex recipe-based products to part mix if they don’t have all the ingredients and then resume the process to complete the recipe when stock levels are replenished, saving time.
Full traceability and the right label information every time
With food scares relating to fresh recipe-based produce hitting the headlines, due to either;
wrong labelling or,
allergen ingredient issues.
Having full traceability and the ability to quarantine batches is critical.
The advanced control, SI integration delivers, fresh food producers can pull off traceability reports in real-time. They can even create their own bespoke labels, using our OCM and labelling module. With SI hub controlling information that is printed onto an individual label, manual processes and the potential for errors, removed. This gives both the food processor and the retail customer, complete confidence in the end product.
Fresh produce secondary processing
For secondary processors, there has never been more opportunity as consumer demand for fresh convenience food continues to increase. For flexibility, greater efficiency and real-time controls of production lines, across multiple processes, ingredients, and defined tolerances, SI’s food ERP is the fresh choice in the fresh produce industry.
To find out more about SI’s Fresh Produce and secondary processing expertise, and how our food ERP and food supply chain planning software could improve control within your fresh food business, simply complete the form and we’ll get right back to you.
“The auditors are always impressed with the speed and accuracy of the system.
We produce records in seconds and the auditors can drill down to see everything; whether it’s details of packaging, labelling, or our raw material, even who signed for it at goods in – it’s all there."
Bearfields of London.
To find out more about how SI can help your food business step up to digital audit management, driven by forward and backward traceability, simply complete the form and we’ll get right back to you.
"With SI, we feel that we can complete any audit within any time limit."
“With Integreater's shop floor data capture, information is captured throughout food processing, giving us complete forward and backward traceability. Now, we can find product history and information in seconds.”
Louise Coulbeck, Director, JCS Fish
SI's shop-floor data capture applications run on touchscreens and intelligence scanners to allow for data capture throughout the production cycle - from intake all the way through to finished goods production and across all operational processes, and stock traceability, as products are stored, recorded and labelled.
With our shop-floor data capture in place, businesses have access to essential, accurate data from the factory floor in real time. Through the use of fixed and mobile data capture points your operation can become paperless and gain access to real-time information and reporting.
Identifying the causes for production downtime
Our manufacturing execution system (MES) provides a detailed view of productivity on a machine at process and departmental level. Set KPIs and, as production data is recorded, assess performance against targets.
When combined with our management tools, including Production Tracker, Stock Tracker and Despatch Tracker, your business will gain unparalleled visibility of performance data throughout your operations.
Gain the real-time advantage with data capture to inform your higher level business applications and analytics.
MES & shop-floor data capture
For almost three decades SI has been perfecting its MES and shop-floor data capture for the food manufacturing industry. Our software accurately captures all production data, validates operational actions, and eliminates the reliance on paper-based records.
By using our modular approach, an SI MES solution will always be built to fit your food business, and any segment of the food processing industry. And as your operations grow, your solution can grow with it, by adding further expert applications from SI.
To find out more about SI’s market-leading shop-floor data capture modules, simply complete the form and we’ll get right back to you.
Live intake reports can be generated to highlight any quantity or weight discrepancies. Whenever product weights differ to what’s been ordered, SI’s Invoice Matching module compares the value of the goods received against the invoice.
Understand supplier performance
Every food processor needs detailed reporting that delivers clarity about purchasing decisions, supplier performance and, ultimately, how cash flow can be optimised.
Our reporting features will enable your purchase management team to track individual team member's product buying patterns. and deliver real-time insight into supplier performance. For instance:
Have deliveries been recorded as either early or late?
Have order deliveries been recorded as fulfilled or shorted?
To find out more about SI’s purchase order processing software and how it could improve efficiencies within your food manufacturing business, simply complete the form and we’ll get right back to you.
Cost Modelling delivers a detailed understanding of a processor’s costs and how they are assigned during the production process, whether direct or indirect. Least Cost Formulation steps up the control as it:
Allows planners to take account of variance in specification of available raw materials (E.g. VL grade), but still attain the strict customer specification & quality (within allowed tolerances), delivering at least cost.
Accounts for all of the costs associated with production, including ingredients, line and equipment changes, and the eventual transfer costs for the mixed product.
Considers staffing and running costs.
Accurately calculates the optimum formulation, a job which would take days to accomplish using spreadsheets; spreadsheets that would be out of date before they are published.
Provides advanced insight into the real costs for finished goods, and in turn offers the opportunity to maximise margin(s).
Transformational benefits for margin management
Today, the combination of our Cost Modelling solution and Least Cost Formulation is solving many of the production planning challenges faced by the meat processing sector.
For both existing and new product lines, LCF shows food processors how to maintain and even support margin growth throughout their operations. So, no matter what consumers, supermarkets and food service customers throw at the sector in the future, SI’s LCF and Cost Modelling applications will be there to support them.
For finance, supply chain and production planning teams, with the responsibility for controlling costs and delivering consistent quality, implementing LCF is transformational and offers measurable returns.
Least Cost Formulation steps up control and takes account of variance in specifications for available raw material.
Want to find out more about how SI’s Least Cost Formulation software can improve your productivity and margins? Simply complete the form and we’ll get right back to you.
Against each price list, a full audit can be maintained for when changes have been made and by whom. And you can maintain and import these lists via Excel, or within SOP; for instance, to apply global price changes by product (for instance +/-% change).
You can store comprehensive pricing by stock code, standard and promotional pricing and for each customer. It also handles offset weeks, where the customer pricing week does not coincide with the supplier pricing week.
For intuitive navigation, price lists can be individually named. Each new price list will detail effectively from/to dates. This can be further broken down to a granular level by product and assigned by customer/s or group.
User-based permissions
With user-based permissions, show, hide or lock off as read-only any information. For multi-sites, set permissions using the drop-down menu feature. Within the Tools taskbar, Despatch Tracker permissions can be set up to determine access to views including the audit history, edit and administer emails, and export to CSV files.
Invoicing
SOP calculates the total value of invoice based on stock pricing, relevant taxes, and any miscellaneous charges created on the order. There’s also the option, within editable invoices, to include credit and debit notes, and to configure for multi-currency.
To find out more about SI’s sales order processing software and how it could improve efficiencies within your food manufacturing business, simply complete the form and we’ll get right back to you.