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Production management and traceability at Diana

About Diana

Diana is one of the leading meat and meat products manufacturers in Romania. Established in 1991, the company has as main activity the sale of food and non-food products. Since 1997, Diana has developed an important technological capacity to produce meat and meat products.

Diana is an important member of the Romanian Meat Association since the beginning of its own products and meat products production. The company holds the ECOPROFIT certification. In 2002, its activity was certified in the Quality Management System, according to the SR EN ISO 9001: 2001 standard and in 2014 Diana obtained the certification according to the ISO 22000 standard.

After 2000, Diana carried out major modernization and refurbishment projects: modernization and new technologies in the preparation plant and pig slaughterhouse (2003-2004) and modernization of the chiller and the abattoir for the beef (2006-2007), SAPARD projects. The audit conducted during this period led to Moody International's Quality Management System and HACCP certification, according to DS 3027 E: 2002 standard.

Here are some eloquent figures:

  • Turnover - over 200 million RON;
  • processed meat / day - approx. 80-100 tons;
  • delivered quantities / day - 50-60 tons of meat products leave every day on the factory;
  • slaughterhouses - 30 cattle / hour, 60 pigs / hour;
  • number of factory employees - 400;
  • number of employees Diana - 611;
  • number of clients - 1,500;
  • orders / day - 650.

The client's need and RBC specialists' solution

Diana team was very precise:

  • They needed double-traceability: Raw material or animal sacrificed to the finished product as well as from the finished product to the raw material / slaughtered animal
  • Full and real-time control of stocks through weighing, scanning and labeling points: raw materials (animals, carcasses, meat), auxiliary materials (spices, packing materials), semi-products (carcasses, anatomical parts), goods
  • Inventory management: What raw materials are being used, what semi-manufactured products are used when they were produced or delivered, what batch these raw materials come from, where were the products packaged, with what warranty were delivered, by which supplier and driver were delivered, at what date
  • Real-time tracking of compliance with product fulfillment conditions
  • Real-time yield control over all production phases based on manufacturing schedules / receipts
  • Interface with current accounting system.

RBC implemented a complete solution, fully covering the client's requirements: consulting, analysis, modeling, installation and parameterization of equipment, software installation and parameterization, training, support and launch in production. RBC solution covers the entire production cycle value chain, from the receipt of the commodity or the slaughtered animal to the delivery of the products, providing all the key performance indicators at each stage and all traceability indicators. They track, control and streamline the parameters of the type: yields, losses, processed volume and efficiency, quality, moves and necessary inventory, traceability and profitability.

In each stage - slaughter, cutting, production - RBC equipment (labels, industrial scanners, scales, printers, etc.) are installed and communicate in real time with the system, transmitting the information in a centralized manner. "Investing in technology helped us have real-time access to any information in the company, to everything that's going on at one point in each section. Now we moved to the second stage, taking online orders directly from the shops", said the company’s representatives.

The system provides rapid information transfer in reports and existing computer systems, such as the ERP system, to get a general overview of the overall activity and each of its stages, rigorous monitoring and control of costs and production planning. Query and control of stock of raw materials and products: The stock level of raw materials and products is known at every moment, providing information on product age, expiry dates, stocking, supplier, and other information needed to plan and schedule production. After inventory analysis, it is decided whether or not there is sufficient raw material on stock to honor orders received from customers, or what quantities and what goods should be produced.

External delivery: Both for the cutting and production stages, the production order is launched after analyzing the existing stock of finished products and raw materials so that it can precisely define - what quantities of products and / or raw materials are on stock, and what quantities of raw materials need to be ordered, when and in what quantities, so processes can be efficiently deployed. For the goods that need to be produced, commodities and spices are ordered when the recipe requests it. Through permanent communication with the ERP solution, raw materials are received, verified, weighed and labeled and reflected in real-time within the system. All relevant information for traceability is recorded, and the material is assigned to those stocks.

Cutting & Production: The flow of operations from Cutting and Production Sections, as well as the equipment required in these operations, are integrated and communicated in real time within the system. This ensures a rigorous control, as well as the corresponding operations.

At the end of each of the complex cycles of cutting and production, we compare in the system that was launched as a Production Order with what has been done and analyze from the point of view of efficiency and efficiency.

Packaging: Full inventory, palletizing and order processing, weighing in each process, inventory control, packaged quantity monitoring, packaging labeling and labeling according to customer's requirements and requirements. Traceability of finished products is complete, going back to the time of receiving the raw material / livestock from the supplier.

Inventory management of finished products and goods: At the end of the production process, some finished products are sent to other Diana sections, where they are inventoried and recorded in the system on other management (Packaging, Freezing, Production etc.) and others go directly into the stock of goods after packaging.

Delivery: Orders are linked to the quantity of merchandise to be delivered to customers. The delivered products are accompanied by complete traceability data that covers the entire production cycle, going back to the supplier of raw materials, livestock or livestock.

Results

"Delivery time diminished. And even more, from slaughter to the output of the factory, everything is recorded. Everything is labeled with barcodes, and on the technology stream you can see where the product comes from, how it was processed. Orders from customers enter the integrated system and at any time one can access the information. There is no risk of losing information or delaying deliveries", says Marin Olteanu, Director of Diana Factory.

By implementing the RBC strategy, we achieved so much: the total and efficient control of the processes of slaughter, cutting, production; monitoring and full control of key performance indicators; keeping traceability by the system, quick and easy reporting in case of problems; Labeling on the entire production stream, according to the current veterinary legislation; rigorous quality control; tracking returns in real time on all production phases based on manufacturing schedules / receipts; increasing productivity and efficiency at the level of the entire process of slaughter, cutting, production; complete stock control over time by weighing, scanning and labeling; knowledge and control of actual production costs; Synchronizing production with existing stocks and orders received, thus avoiding over-production and being more cost-effective; promptness and fairness in the delivery of orders, which has led to customer loyalty and elimination of returns; multiple reports, rigorous and at all times; interface with the accounting system; optimizing inventories, costs, processes, leading to profit optimization.

“Collaboration with RBC was not just good, but very good. The results are noticeable by now, but the amortization of the investment will last about 5 years, as any good and serious endeavor. But the results are visible simply because we have all the data about production, about sales at time 0. Like any car: when you add a component, it gets better. We already had a functional IT system, but I can say that with the implementation of the RBC integrated system, we have moved from Trabant to Audi or Mercedes, "said the representatives of the company.

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