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High Volume Food and Beverage Case Study www.cedar-bay.com Engineering Project / Manufacturing & Distribution / Food & Beverage / Oil & Gas / Automotive / Medical The Company Established in 1990, ICB has grown quickly and now supplies alcoholic drinks to most of the UK’s leading supermarkets, convenience chains and wholesalers. They also export to Germany, Scandinavia, Africa, Hong Kong, Australia and several other sport markets. Between 2007 and 2012, the company went through a significant capital investment programme in its alcoholic drinks production, capability and flexibility of its packaging operations. In 2011, ICB invested in a production business in Herefordshire to assure its fermented liquid supplies into the future. ICB has become the UK’s leading supplier of Speciality Drinks and offers a range of brands that provide a value alternative to many of the more expensive and better known brands. They have also enjoyed considerable success in several other categories e.g. Pre Mixed Drinks (cocktails and RTD’s), Cider, Perry and Wine. The ICB Production Facility ICB’s alcoholic drinks production facility is in Middlesbrough where around ninety staff are employed in various operational roles: production, warehousing, packaging, engineering, procurement, product development, quality control and assurance, technical support, supply chain, finance and admin. • The alcoholic drinks production facility has three glass bottling lines, one PET bottling line and one bag- in-box line. • ICB produces c.25 million bottles of alcoholic drinks every year. • The total storage capacity on site is over half a million litres with vessels ranging in size from 20,000 to 100,000 litres. • ICB handles a variety of fermented liquids (grape, pear, apple). • ICB also contract packs for other alcoholic beverage suppliers. • ICB production facility is British Retail Consortium accredited and holds quality certifications/customer accreditations from many of the UK’s leading supermarket chains, including Lidl and Tesco. ICB are a signatory to The Portman Group and supporters of the Drink Aware campaign. ICB is very proud of its production facility, its staff and the quality of the products that it produces. The IFS Story ICB selected IFS as their chosen ERP vendor in late 2012. The Cedar Bay RF solution was provided as part of the IFS solution to meet ICB’s RF/Data Capture requirements. ICB had short and aggressive timescales to implement the project and their project team was managed by Matt Brown. As is the norm with an implementation where Cedar Bay are implementing alongside IFS, the initial training and installation of IFS was done by the IFS team. This allowed the initial process design to be documented.

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Page 1: High Volume Food and Beverage Case Study - Cedar Bay · ICB are a signatory to The Portman Group and supporters of the Drink ... The Cedar Bay RF solution was provided as part

HighVolumeFoodandBeverageCaseStudy

www.cedar-bay.com EngineeringProject/Manufacturing&Distribution/Food&Beverage/Oil&Gas/Automotive/Medical

TheCompany

Establishedin1990,ICBhasgrownquicklyandnowsuppliesalcoholicdrinkstomostoftheUK’sleadingsupermarkets,conveniencechainsandwholesalers.TheyalsoexporttoGermany,Scandinavia,Africa,HongKong,Australiaandseveralothersportmarkets.Between2007and2012,thecompanywentthroughasignificantcapitalinvestmentprogrammeinitsalcoholicdrinksproduction,capabilityandflexibilityofitspackagingoperations.In2011,ICBinvestedinaproductionbusinessinHerefordshiretoassureitsfermentedliquidsuppliesintothefuture.ICBhasbecometheUK’sleadingsupplierofSpecialityDrinksandoffersarangeofbrandsthatprovideavaluealternativetomanyofthemoreexpensiveandbetterknownbrands.Theyhavealsoenjoyedconsiderablesuccessinseveralothercategoriese.g.PreMixedDrinks(cocktailsandRTD’s),Cider,PerryandWine.

TheICBProductionFacility

ICB’salcoholicdrinksproductionfacilityisinMiddlesbroughwherearoundninetystaffareemployedinvariousoperationalroles:production,warehousing,packaging,engineering,procurement,productdevelopment,qualitycontrolandassurance,technicalsupport,supplychain,financeandadmin.

• Thealcoholicdrinksproductionfacilityhasthreeglassbottlinglines,onePETbottlinglineandonebag-in-boxline.

• ICBproducesc.25millionbottlesofalcoholicdrinkseveryyear.• Thetotalstoragecapacityonsiteisoverhalfamillionlitreswithvesselsranginginsizefrom20,000to

100,000litres.• ICBhandlesavarietyoffermentedliquids(grape,pear,apple).• ICBalsocontractpacksforotheralcoholicbeveragesuppliers.• ICBproductionfacilityisBritishRetailConsortiumaccreditedandholdsqualitycertifications/customer

accreditationsfrommanyoftheUK’sleadingsupermarketchains,includingLidlandTesco.ICBareasignatorytoThePortmanGroupandsupportersoftheDrinkAwarecampaign.ICBisveryproudofitsproductionfacility,itsstaffandthequalityoftheproductsthatitproduces.

TheIFSStory

ICBselectedIFSastheirchosenERPvendorinlate2012.TheCedarBayRFsolutionwasprovidedaspartoftheIFSsolutiontomeetICB’sRF/DataCapturerequirements.ICBhadshortandaggressivetimescalestoimplementtheprojectandtheirprojectteamwasmanagedbyMattBrown.AsisthenormwithanimplementationwhereCedarBayareimplementingalongsideIFS,theinitialtrainingandinstallationofIFSwasdonebytheIFSteam.Thisallowedtheinitialprocessdesigntobedocumented.

Page 2: High Volume Food and Beverage Case Study - Cedar Bay · ICB are a signatory to The Portman Group and supporters of the Drink ... The Cedar Bay RF solution was provided as part

HighVolumeFoodandBeverageCaseStudy

www.cedar-bay.com EngineeringProject/Manufacturing&Distribution/Food&Beverage/Oil&Gas/Automotive/Medical

TheCedarBayteamvisitedthesiteinajointmeetingwiththeICBprojectteamandtheIFSlogisticsconsultants.TheCedarBayprojectmanager,GrahamWiley,andoneoftheCedarBaydirectors,RogerTeagle,walkedthroughtheprocesswiththeteamtounderstandthephysicalenvironmentandunderstand,atahighlevel,howtheIFSprocessedwerebeginningtobedeveloped.ICBalreadyhadascanningsolutionwithintheirlegacysystemandwereusingMotorolaMC9090scanners,sotheyhadalargeamountofbarcodedpalletsandmaterialsalreadyinstoresandalotofthesupplierswerealreadydeliveringadequatelylabelledgoods.ThenextphasewastodemonstratetheCedarBaysolutiontoICBinthecontextofwhattheyweretryingtoachieve.Atthisstage,theprojectteamwerealreadyfacedwithsomechallengesastohowtheIFSprojectwouldsupportsomeoftheICBbusinessprocesses.Thekeyoneamongstthiswasaroundthewaythatfinishedgoods(stock)isstoredandpicked.ICBpickfullpalletsandmixedpallets,andwhileFIFOpickinglogicissuitableforpickingfullpalletorders,itreducestheflexibilityofthemixedpalletpickingteamwhoneedtobeabletochoosewhichlotbatchtheywanttopick.Toovercomethis,CedarBayproposedusingaprocesswherethescannerisusedtocreateareservationratherthanapick.Thisenabledtheusertoscanorenteracustomerordernumbertodisplayalltheopenorderlinedetails.Thengotoaneasytoreachpalletlabel,scanthelocationandenterthequantity.Thisthencreatedmanualreservationsincrementallyinthebackgrounduntiltheorderlinequantitywassatisfied.Atthispoint,anyremainingopenorderlineswerethendisplayedfortheusertoselectandcontinuescanningpallets.Oncealltheorderlineswereprocessed,theuserthenconfirmedallthepalletshadbeenreservedandtheorderwasreadytobedelivered.

DayOnewithCedarBay

Page 3: High Volume Food and Beverage Case Study - Cedar Bay · ICB are a signatory to The Portman Group and supporters of the Drink ... The Cedar Bay RF solution was provided as part

HighVolumeFoodandBeverageCaseStudy

www.cedar-bay.com EngineeringProject/Manufacturing&Distribution/Food&Beverage/Oil&Gas/Automotive/Medical

ManagingPallets

ICBdecidedtocreateauniquelot/batchnumberforeachpalletofmaterialsreceivedviatheCedarBayPOarrival/labelprinttransaction.Thelot/batchnumberwasprintedonthepalletlabel.Allusersthenhadtodowastosimplyscanthissamebarcodeforallsubsequentinventorytransactions.CedarBaywasabletoderiveallthenecessaryinformationfromthistocompleteeachtransaction.TheCedarBaymoveinventorytransactionsimplifiedthemovementofstock.AsICBhaveamixtureofpalletisedandnon-palletisedinventory,itwouldhavebeendifficultforausertodetermineifastandardmoveoranexecutiontaskwasrequired.Thelogicbuiltintothistransactiondeterminedifthestockwaspalletisedornot,andperformtherequiredprocesstoautomaticallycreateandexecuteatransporttaskforpalletisedpartsorsimplymovethelot/batchquantityifnot.CedarBayworkedwiththeICBteamonlabellingtohelpcreatelabelsforthegoodsfrommanufacturing.TherewererequirementsfromICBforextrahandhelddevicesandCedarBaysourcesandhelpsettheseup.ThenewdeviceswereMotorolaMC9100astheolddeviceshadbeensuperseded.

Implementation

CedarBayprovidedsupporttoICBduringthepilotingphaseandthereweresomesmallchangesthatweremadetothesoftwaretoincorporatesomerequirementsthatICBhad.ThecompletedesignwithallofthemoduleconfigurationsandsetupswerefullydocumentedbytheCedarBayprojectmanager,thisbecomestheblueprintfortheCedarBaysystemusedatICB.Oncethepilotenvironmentwascreated,ICBrantheirownpilotprocessesandthenprovidedtheirstaffwithendusertrainingonthedevicesandthesoftware.ICBwentlivewithIFSandCedarBayinAugust2013andhaveimplementedtheRFsolutionacrossthewholefacility.

TheScopeoftheProject

Thebroadscopeisasfollows:1. POreceiptwithEANlabelprinting2. POmovetostockincorporatingbestbefore

date3. Countpercountreport4. Shoporderpicking5. Shoporderreceiptandlabelprint6. Shoporderun-issueincorporatingreport

componentscrap7. Movementofpalletisedgoods(creationof

transporttaskaspartofaninventorymove)8. Customerorderpick9. Customerorderreserve10. Partavailabilitychange

Page 4: High Volume Food and Beverage Case Study - Cedar Bay · ICB are a signatory to The Portman Group and supporters of the Drink ... The Cedar Bay RF solution was provided as part

HighVolumeFoodandBeverageCaseStudy

www.cedar-bay.com EngineeringProject/Manufacturing&Distribution/Food&Beverage/Oil&Gas/Automotive/Medical

NextSteps

ThebusinessplantolookatfurtherstreamliningoftheICBprocessesusingtheCedarBaysolution.ThenextstepsaretolookathowtabletscanbeusedontheshopfloorforrecordingdataagainstIFSmanufacturingcontrolplans.Thiswillstreamlinethereportingofin-processinspectionresultsintoIFS.

Tel:+44(0)1242304244e-mail:[email protected]

Address:CedarBayLtd,HermesHouse,AndoversfordLink,AndoversfordIndustrialEstate,Andoversford,Glos,GL544LB,UK

Howcanwehelpyou?Contactus!

TheResults

Only5weeksaftertheimplementation,MattBrown,ICBProjectManager,wassopleasedwiththeworkthatCedarBayhaddone,heofferedtotakeaCedarBayprospectonareferencesitevisit.Duringthereferencevisit,MattexplainedtheprocessedthatICBwerefollowingintheirproductionandwarehousingareas.MattdemonstratedhowtheCedarBaysolutionwasusedbytheproductionandwarehousingoperators,payingparticularattentiontohowthehandhelddeviceswerebeingusedincombinationwithbarcodingtosimplifyvariousprocesses.Duringthevisit,theCedarBayprospectwastakentothewarehousewhereanoperatorexplainedthattheCedarBaysolutionwasextremelyeasytooperate.Mattalsoaddedthatthewarehouseoperatorsmadefewermistakesnowandweremoreeffectiveintheirjobsnowtheyhadmobiletechnologythatsupportedthem.Intheproductionarea,itwasdemonstratedhowthematerialswereissuedandunissuedtotheshopordersthenfinishedshopordersweresimplyreported,receivedandputawayusingtheCedarBaysolution.Attheendofthereferencevisit,Mattexplainedtotheprospectthathewasverypleasedwiththebackground,experience,adviceandsupportthathereceivedfromtheconsultingandtechnicalteamsatCedarBay.


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