performance. sustainability. compliance. customer name presentation – july 2012

Performance. Sustainability. Compliance.

Customer Name Presentation – July 2012

Use of Materials

The following materials are provided solely for purposes of evaluating a potential business opportunity, and with the mutual understanding that they will not be copied, re-distributed, or used for any other purpose.

Vigilistics Confidential.

Vigilistics: Enterprise Process Reporting

• Process Monitoring, with dashboards and KPI

• Scientific Analysis, with enterprise benchmarking

• Scalable, analysis enriched data; easy to use and share

• Process and Quality reporting, with FDA validation


Dairy Processing Challenges

The Use of Technology to Increase Transparency and Shorten Corrective Action Cycles means less Shrink

Record Keeping under

FSMA

Process Monitoring and

Reporting

Exception Management

Corrective Actions

Benchmarking, Variance and Root Cause Analysis


Comprehensive Suite for Dairy


Compliance (CIP, COP) Material Loss/Yield Traceability Chemicals Utilities Analytics

Milk-Loss Overview

Configurable, Maintainable System• Configurator for automated PLC/HMI integration• Units, Areas, Inventory • Product Types and Classes, with standards• SKUs, Molds, target weights

Designed for Milk Processors• Bulk Receiving and Loadout, Inventory, Quality, Pasteurized

production, Filling Room, Rework, Blow Mold and SKU weight, Volume and BF variances, Performance by Hauler, or Operator . . .

• Accounting Adjusting Entry support (One Record!)• Production Planning included• Configurable real-time Alerts • Live Plant-wide and drill-down Views


Milk-Loss Focus Area


Misc.

Receiving

Mix / Blend

Piping

Filling / Packaging

20%

10%

10%10%

30%

20%

Pasteurizing

Receiving

• Problem: • Farm samples and declared weights• Supplier Variances in volume and BF• Operator logs and process records differ from accounting

• Solution:• Automated or Keyed record entry, with Accounting adjusts• Metered Volume vs. Declared, integrated BF tests• Real time notifications of variances

• Opportunity:• Average Milk-loss of 0.25%, BF variance of 0.1%• One Record = Less headache!


Standardization

• Problem: Batch Standardization Lack of reporting on batch details Lack of visibility to batch frequency and losses Too much finger-pointing over shortages

• Solution: Integrate lab results, calculate BF standardization

loss Easily accessible reports for Production Planning

• Opportunity: Big BF opportunity depending on mix $10,000/month in Standardization and

Improved Production Planning


Filling Room

• Overfill and Throughput Lack of standards or control of overfill Managing production against ordered quantity Achieving throughput

• Solution: Real Time Weights Sampling, with predefined

targets Production Planning by SKU Real-time view of buffer storage and production

• Opportunity: Up to 0.5% in reduced overfill


Engineering


• Old, hard to maintain process controls Not practical to add new features Current process control strategy not supported by

existing controls

• Solution: Process Reporting can be an effective means of

augmenting current control systems Measure/standardize pasteurizer change-overs Integrate Allergen Awareness into CIP process

• Opportunity: Extend the useful life of current control systems

Blow Mold Management

• Process Variances Inconsistent weight of blow molded containers

• Solution: Real-time weight collection for each mold Identify performance by Shift by Operator

• Opportunity: 1 gram per 1 gallon jug x 80,000/day = $150/day Or, around $40-50,000/year!


Administrative Reporting

• Headcount dedicated to daily reporting Handwritten logs problematic for SQF and QA Transposing logs into Excel and into reports Production Planning repeats the laborious process

• Solution: Automated reporting with Acctg

Review/adjustments Integrated Production Planning Result: One Record of Production!

• Opportunity: Free up one headcount to do productive work


Audit/Inspection Readiness


• Too much paper! Time spent filing and retrieving, and space for storage Increasing need for auditable records What is the plan for documented process for FSMA?

• Solution: One Record, automated online reports Ability to delegate Audit Readiness to Supervisors

• Opportunity: How many hours and days would you save

annually? Improved Quality Ethic throughout the staff

Managing Plant Performance


• Yesterdays loss number isn’t actionable No ability to assign loss to operating area Operations and Accounting never agree Problems within the day . . . If I had known!

• Solution: Live view of Receiving, Pasteurizing, Filling,

Loadout Define real-time variances to drive Exceptions Integrated, single record between Ops and Acctg.

• Opportunity: You get what you measure -- >0.5% more

bottled

Managing for Continuous Improvement

The Future


Connected, Integrated Plant Plant reporting to Enterprise Standards Anytime Inspection & Audit Status Agility and Supportability Shared Best Practices

Next Steps

• Select KPIs • Set initial Benchmarks • System Pilot

Automated, Accounting Supported, Real-time and Daily Performance Reporting


Performance. Sustainability. Compliance.

Thank You

www.vigilistics.com (949) 900-8380

performance. sustainability. compliance. customer name presentation – july 2012

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