Hillshire Brands: Manufacturing Intelligence Key Ingredient in Food Safety Modernization Act Compliance

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The Food Safety Modernization Act requires food producers to take new preventative measures against food borne illness hazards. Hillshire Brands, a global leader in packaged meat and bakery production, has expanded scalable manufacturing intelligence solutions based on FactoryTalk software to meet new guidelines. Production facilities currently log 100 to 2,000 data points. Centralized trend reporting and analytics enabled on mobile devices and advanced alerts are helping to more tightly control production, bolster reporting and track and trace capabilities, and even increase production flexibility.

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Hillshire Brands: Manufacturing Intelligence Key Ingredient in Food Safety Modernization Act Compliance

  1. 1. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Hillshire Brands: Manufacturing Intelligence Key Ingredient in Food Safety Modernization Act Compliance
  2. 2. Agenda • Introductions • Overview of FSMA • Product traceability • Examples of applications
  3. 3. Introductions Ian Tooke Grantek Systems Director of Consulting – 705.241.0429 Ian.Tooke@Grantek.com Jon Riechert Hillshire Brands Sr. Engineer - Innovation jonathan.riechert@hillshirebrands.com
  4. 4. Hillshire Brands Overview • $4 billion in annual sales • Manufacturer of Processed Meats and Baked Goods • Headquartered in Chicago, IL • Formerly Sara Lee • Coffee and Tea business spun off in July 2012
  5. 5. Hillshire Brands Overview • 11 Manufacturing facilities, 5 regional distribution centers in the US • 1.8 billion pounds of production
  6. 6. About Jon Riechert • Part of Corporate Engineering group • Responsible for capital projects • Innovation and new products • Electrical Controls Standards • Data Collection and Reporting
  7. 7. Product Traceability at Multiple Levels
  8. 8. What is the Food Safety Modernization Act? Food manufacturers are watching as the Food Safety Modernization Act (FSMA) evolves to the next level as comprehensive transformation of food safety laws are developing. The focus of the FSMA is to shift food contamination responsibility from response to prevention.
  9. 9. How will the Food Safety Modernization Act Impact My Food Manufacturing Operations? As a result of the FSMA, manufacturers need to be proactive and start thinking about how the FSMA will impact: • Manufacturing plants • Manufacturing business systems • Production methods • Supply chain
  10. 10. Current Project - Background • Corn Dog facility making 120MM pounds annually near Fort Worth, TX • Collecting data from all over the plant • Utilities, Processing, and Packaging ~1500 data points • Enabling management to be more responsive to changes • Running a pilot of VP Mobile platform
  11. 11. Current Project - Goals • Use data to improve transition from sanitation to production • End of day production report • Yields and pounds produced by SKU • By area and for entire facility together • Food safety traceability • Mobility to promote communication and flexibility
  12. 12. Food Safety Focus Areas • Process data • Product distribution/flow through plant • Packaging verification • Reporting
  13. 13. Food Safety - Processes • Verification of process parameters • Current back up to quality reporting • Possible replacement • Processes involved • Cooking (CCP) • Chilling/Freezing (CCP) • Frying • Clean in Place systems
  14. 14. Cook Process
  15. 15. Chilling/Freezing Process
  16. 16. CIP Chart Recording
  17. 17. Quality Reporting
  18. 18. Food Safety Example • Issue with cooking sausage to proper temperature • Able to use FactoryTalk ® Historian and FactoryTalk VantagePoint to identify issue
  19. 19. Food Safety Example
  20. 20. Food Safety Example
  21. 21. Food Safety Example
  22. 22. Product Distribution • Important to track product as it flows through plant • 12 Fryers to 15 Pack lines • We monitor distribution settings • Provides traceability from packaging back to earlier processes
  23. 23. Product Distribution B1 B2 IW1 IW2 IW3 IW4 IW5 IW6 IW7 IW8 C1 C2 IW13 IW14 IW15 B3 Fryer 1 X X Fryer 2 X X Fryer 3 X X Fryer 4 X X X X Fryer 5 X X X X Fryer 6 X X X X Fryer 7 X X X X Fryer 8 X X X X Fryer 9 X X X X Fryer 10 X X X X Fryer 13 X X X Fryer 14 X X X Pack Lines
  24. 24. Packaging Verification • Want to ensure that proper packaging is being used for products • Concerns around allergens, nutritional info • Checks packaging pulled from inventory • Checks supplier process
  25. 25. Packaging Verification - Current
  26. 26. Packaging Verification - Future
  27. 27. Product Tracking • Working to utilize print on demand case label • Adding 2D bar code • Case serial # • Line # • Date/Time • SKU • Weight
  28. 28. Product Tracking
  29. 29. Product Tracking
  30. 30. Product Tracking • 00001_0145_1411061314_16024_3300 • Allows for reporting to track case back through plant to beginning of product • Can get very specific on number of cases produced • By line • Within timeframe • Reduces product placed on QA hold
  31. 31. Production Reports – In Portal
  32. 32. Production Reports – In Excel
  33. 33. Who we are… A leading provider of automation, process, safety and business intelligence solutions • Founded in 1980 (30th Anniversary) • ~145 Employees Office Locations • Chicago, IL • Allentown, PA • Barrie, ON • Toronto, ON • Cleveland, OH • Montreal, QC • Moline, IL • Vancouver, BC
  34. 34. Who we are… Electrical Engineering 18 Automation 75 Validation 14 ERP Interface 7 Business Intelligence 28 Grantek is the 1st company world wide with all four certifications. Enterprise
  35. 35. Grantek Clients
  36. 36. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. We care what you think!  On the mobile app: 1. Locate session using Schedule or Agenda Builder 2. Click on the thumbs up icon on the lower right corner of the session detail 3. Complete survey 4. Click the Submit Form button 38 Please take a couple minutes to complete a quick session survey to tell us how we’re doing. 2 3 4 1 Thank you!!
  37. 37. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Thank you for attending our session! Contact Us michael.lohmeyer@grantek.com

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