Foster Farms Dairy
Fresno & Modesto, CA
milk and dairy product producer
Challenge:
Foster Farms Dairy has an IB AS/400 mainframe for accounting and sales. However, they had nothing to schedule or track production in the plant. For Quality Control, they were using a proprietary, stand-alone system.
Mission:
- Develop a manufacturing execution system.
- Integrate with the AS/400.
- Integrate with plant equipment (PLC's) to capture production data.
Our Solution:
We developed a web-based, Microsoft .NET®, Microsoft SQL Server® to meet their goals.
Scheduling
- Based on AS/400 sales and scheduled deliveries, create fill schedules, taking into consideration current warehouse inventory and recommended inventory levels.
- Create a pasteurizer schedule to satisfy the fill schedule.
Inventory Control
- Hand-held bar-code units to take daily inventory of finish product and raw materials.
- Ability to maintain minimum levels of finished goods and raw materials.
- Ability to monitor liquid levels in bulk tanks in real time.
Production
- Real time monitoring of production throughout the day.
- View Fill Schedule for each fill line or for the entire plant.
Material Requirements Planning
- Generate purchase orders for raw materials based on inventory levels and future production needs.
Quality Assurance
- Set up parameters for lab tests.
- Document finished goods lab tests.
- Document raw materials lab tests.
- QA Configuration:
- Tests.
- Batch defaults.
- Customers and their exceptions.
- Sources.
Shipping/Receiving
- Milk receiving.
- Condensed receiving.
- Lab test entry.
- Cream shipping.
System configuration
Our system allows you to configure the following items at a minimum:
- Brands.
- Container sizes and types.
- Product lines.
- Inventory master (finished goods, raw material, outside product).
- UPC and product codes.
- Product Recipes.
Reports
- Daily milk accountability.
- Production in gallons/lbs/units.
- Production by product line.
- Condensed usage.
- Condensed receipts.
- Milk receipts.
- Daily inventory.
- Daily/weekly/monthly production.
- Daily schedule.
- Daily/monthly sales.
- Finished goods lab test results.
- Month-end Ingredient usage.
- Milk receipts by dairy/source, etc.
- Product recipes.
- QA results in text and graph form.
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