LEADING IN EUROPE thanks to a powerful industry solution. The complete automation technology is seamlessly integrated with the software from SLA

Transcription

1 BMR Schlachthof Garrel: LEADING IN EUROPE thanks to a powerful industry solution The complete automation technology is seamlessly integrated with the software from SLA Management Summary The BMR Schlachthof Garrel GmbH, a slaughterhouse in Garrel, near Cloppenburg in Germany, is one of the most successful slaughter businesses in Europe, thanks to modern automation technology, efficient processes, motivated employees and powerful industry software. Pressure to rationalize its business in the form of The manual capture and documentation of data during the slaughter process is no longer viable. In order to be able to react to the requirements of the customers and the market, respond immediately to new business options and to achieve stable growth, the management of BMR decided to implement an industry solution in the mid- 1990s. After using a less capable software solution from a competitor, they decided on a co-operation with the SLA in 2000 and the increasing slaughter numbers, new legal requirements and the need for complete traceability moved the BMR to implement the industry solution -Office from SLA in With success! In the meantime, the pure porcine slaughter business, which acts as a service provider in the halves business, is among the ten largest slaughter houses in Germany. implementation of SLA -Office. SLA -Office is a solution especially designed for the needs of the meat processing industry and offers the complete integration of all business processes. Alongside the commercially oriented functions, the solution also makes it possible to connect industry specific peripherals, such as the Fat-O-Meter (FOM), AutoFOM, scales, label printers, pricing machines, 1

2 PLC management and classification system in real time. BMR used the complete hardware and software package from the SLA for the area of animal registration. During the slaughter process all of the data, from the delivery ramp through to the cool house management and dispatch is collected in the system. Additionally, the programmable logic controller (PLC) is seamlessly integrated, which allows for complete process mapping. In the future even the byproducts will be more quickly and efficiently calculated using the solution. A project for this is already in the planning stage. With the use of SLA -Office a much WITH SLA -OFFICE WE HAVE REALIZED A VERY HIGH LEVEL OF AUTOMATION IN THE COMPLETE CHAIN, INCLUDING THE LOGISTICS PROCESSES. Peter Moormann, CEO higher level of automation in the complete production chain, including the logistics processes, can be realized. The system makes production data available in realtime and offers the possibility for quicker, informed decisions to be reached. Quantity and the origin of a delivery are captured at the ramp using the delivery note and video recording and passed to the system. INTEGRATED PROCESSES THANKS TO SLA -OFFICE Here the salmonella status of the (PLC) from the company AIS, which farmer is automatically compared to the supports and manages the slaughter information in the Qualiproof database. process, is integrated into the system in For the classification of the carcasses, exactly the same way as all of the other the solution retrieves the data from the peripherals. The external grade (SEUROP FOM or the newer AutoFOM systems and M1 M2 V), which defines the grade of also controls the weighing process as the slaughtered pig, are automatically well as all following processes. With the calculated based on defined criteria and the classification using the AutoFOM around classification data. 2,000 raw data points for each animal are An internal classification, which was collected through ultrasound sensors, developed together with SLA, also gives the which are used to generate 127 fat and carcass an internal grade, meat thickness readings. The existing programmable logic controller 2

3 which are used to control further processes, such as the sorting into the cool house. This is flexible and can be changed at any time to suite the customer s requirements. At the meat inspection stage the SLA solution supports the veterinary workers on the slaughter line with specially developed touch screen terminals, through which the findings and animal welfare data can be entered, which is also made available in real time. Definitions and the number of findings and complaints are freely definable for each inspection point through the SLA system and can be changed at any time. Carcasses with damage are diverted to a secondary line for further work (E.g to remove boils, cuts, bad meat etc.). The carcass is then automatically fed back into the main slaughter process. In total there are 30 work places that are configured to work the SLA solution, that includes all of the scales that are used to classify the meat, both of the inspection terminals and the work place in the inspection room, where unclear findings can be more closely inspected. All further SLA work places are in the back office area. BMR has successfully used the industry solution from SLA for many years 3

4 LOWER COSTS AND HIGHER QUALITY, THANKS TO AUTOMATED STORAGE With the installation of the SLA solution, the BMR workers moved out of the cool house. The fully automatic targeting system from SLA, implemented in 2009, allows the automatic selection and storage of carcasses based on quality and customer preferences. The halves are transported to defined positions in the cool-house without the need for carcasses to be manhandled, based on internal grades and customer specifications. The next day, the halves are then removed from the cool-house and dispatched using a fully automated process, based on customer sorting. This is an excellent example of how we not only save on personnel costs, but at the same time improve the sorting and minimize the chances for microbial contamination, through the use of intelligent IT, said Moormann. TRANSPARENCY AND SECURITY THANKS TO RFID-TECHNOLOGY In the age of meat scandals, transparency and safety during the slaughter process WITH THE USE OF RFID TECHNOLOGY BMR ATTAINS 100 PERCENT TRACEBILITY OF ALL PRODUCT COMPONENTS THROUGH THE PROCESS CHAIN. is a major theme, alongside economy. The traceability of the animals today begins with delivery. Here the number, origin and state of the animals per delivery note and video recording are documented. After the scraping machine the carcass becomes a slaughter number, which is linked to the RFID chip built into the meat hook, whereby the origin of the pig is stored. The pig is then identifiable through the transponder number in the system, the dataset, which is expanded during the slaughter process, can be called up in real time from every work place. 4 UNDERSTANDING THE POTENTIAL OF ERROR ANALYSIS With a throughput of 98 percent the slaughterhouse BMR counts itself among the most successful businesses Europe, in Germany it is currently ranked at place 7. Moormann ascribes this success to the proven combination of powerful industry software and motivated employees. In order to keep this up and to quickly find and fix errors, he has a weekly round table meeting with his management team. Here it is not about the CEO laying blame on others, but about a objective causal research. The outages can be traced back to faulty hardware in sundry systems 99% of the time, explains Moormann. In order to more quickly localize the cause of a defect, I have the complete slaughterhouse graphically visualized on my computer. The visualization program is a further component in the error analysis. With this tool the qualified electrical engineer with a passion for automation technology can call. up the current throughput of the slaughter line at any time.

5 SLA SUPPORT, A CORNERSTONE TO SUCCESS Quick and technically versed support restructuring of the slaughter line to use is a critical factor in our business.if the modern RFID technology and the cool slaughter line stands still, 100 people house management, for example, were have to wait around until it starts running implemented in just a single weekend. On again, I get extremely nervous, stressed the following Monday everything simply Moormann. It is therefore good to know, worked, which amazed and pleased CEO that at the SLA somebody is available Peter Moorman in equal measure. around the clock, 7 days a week and takes For our slaughter process, the SLA on responsibility for fixing the problem. solution with its extensive functionality and The co-operation with the SLA has been its well thought out management tools has excellent. All projects are implemented become indispensable. to our satisfaction by the Quakebruck IT specialists within a couple of weeks. The BACKGROUND INFORMATION ABOUT BMR The initials of the company name, BMR, come from the names of the stock holders: the Steinfeld businessman Christian Bloemer, the Hans Mueller-Ricken GmbH from Borger and the Raiffeisen Animal Marketing. The CEO is Peter Moormann. Since its grounding in 1999 the medium sized business has continually expanded. Currently on the site of around 5 hectares processes around 1.5 million animals, with 25 to 30 percent going to export. This places BMR Garrel at place 7 in the German slaughterhouse rankings. Currently the company has 100 qualified employees, 45 of which are on the slaughter line, 20 in dispatch and picking, 15 in meat inspection as well as 15 technical and administration staff. The delivered pigs, in total 10 to 15 different types, are slaughtered in Garrel and then cooled and finally loaded onto trucks. Every part is utilized, the by-products are sold directly by the company itself. 5

6 SLA The SLA Software Logistik Artland GmbH, based in Quakenbruck, has been optimizing business and production processes in the food industry since With extensive industry knowledge, solutions are implemented, supplemented and connected to all modern peripheral devices including RFID systems in the production process, in order to make company workflows more efficient, more secure and more profitable. SLA is the market leader in Europe for solutions for meat processing from slaughter on. A further business area is comprehensive internet applications such as the MEAT INTEG- RITY SOLUTION (MIS) and industry portals such as GLOBALG.A.P. as well as POS apps for sales. The company s own industry PCs and software components for third-party providers complete its product range. SLA s customers include Bedford, Bell, Rügenwalder Mühle, SFZU/Ulmer Fleisch, VION and Westfleisch. You can find more information online at SLA Software Logistik Artland GmbH Friedrichstr. 30 D Quakenbrück Tel: +49 (0) Fax: +49 (0) kontakt@sla.de Image rights: SLA Software Logistik Artland GmbH, Quakenbrück 6