QUICCA utilization example Vol.2
To the management and executives of food factories,
QUICCA can reduce raw materials
Low-margin food industry
Statistics show that the average profit margin in the food industry is less than 3% in Japan. The food industry makes things that are essential for people to live, and it is not easily affected by economic fluctuations, but the business is less profitable compared to 10% in the machine tool industry and 6% in the electronic parts industry. Among foods, raw material costs account for a particularly high proportion, and products with a short shelf life, such as processed meat products and bread products, currently have a profit margin of around 2% even for top-class companies in the industry. Think about how you can reduce the waste of raw materials.
The table below shows how much profit can be generated by eliminating 1% of waste of raw materials. You can see that it will be a considerable amount of money (raw material consumption is calculated at 100 tons / month).
(yen / kg)
(10,000 yen / month)
|1% cost reduction
(10,000 yen / month)
|1% cost reduction
(10,000 yen / year)
How to eliminate waste of raw materials
So how can we eliminate the waste of raw materials? The graph below is a histogram showing the distribution of weight variations in the final product. Nothing is less than the weight indicated on the package (100g this time), and even if all of the finished products can be shipped, more products can be produced in the left distribution, which is closer to the nominal weight, than the right distribution. The state shown on the right indicates the production is using extra raw materials.
Histogram should be viewed in real time
Take hamburger production as an example. After mixing minced meat, chopped vegetables, bread crumbs, seasonings, etc., there is molding process to make it into a hamburger patty. In the process of extruding raw materials with the same pressure and die-cutting at the same speed, the operator makes delicate machine adjustments. The weight will vary depending on the viscosity, temperature, and pressure applied to the object. After that, the process of baking, coating, freezing, packaging, etc. continues, but since the weight changes from process to process, a Checkweigher is usually used to check the weight when it becomes a product.
To reduce the waste of raw materials, it is necessary to quickly inform the workers of the upstream molding process about the tendency of the product mass is increasing. As many factories rely on verbal communication that may need time, it is no effective when check the tendency with the histogram on the checkweigher screen after the production is finished.
Feedback of product mass fluctuations to the molding process
Mass fluctuations do not appear randomly but are often biased in the positive or negative direction over time. In other words, if you adjust the molding machine while looking sideways to see if the shape of the histogram is different from usual, it will be possible to make the product weight constant and uniform. First, install QUICCA (Anritsu’s quality management system) on the production manager's personal computer, and connect the PC and each inspection machine via LAN. Administrators can then view the histogram in real time from a distance at any time.
Features and Advantages of QUICCA
- Acquire data of multiple Checkweighers in real time and update histograms and statistical data.
- Histogram, average value, and production volume are displayed in real time on the screen for each product and line.
- If you use a remote desktop app, you can share the screen even on devices that do not have QUICCA installed.
The third point (screen sharing) is important. Since the worker in the molding process holds the tablet and adjusts the molding machine while looking at the same screen as the PC on which QUICCA is installed, the weight can be adjusted in a timely and appropriate manner.
As a result, waste of raw materials can be significantly reduced, which can greatly contribute to profit generation. Please consider introducing QUICCA. We also rent out PCs with QUICCA installed and tablets for screen sharing.
Contact us for inquiries .
Creating a histogram and devising countermeasures is an effective way to see the tendency of product weight variations. Take that idea one step further and look at the histogram during production to find signs of problems. With QUICCA, you can share problems with the field in real time and respond immediately to generate profits.
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