A Slovak dairy supplying its products to several EU countries approached us with a request for digitalization and increased production efficiency. Our solution significantly accelerated the search for sources of infections and contamination. Real-time production control and elimination of human error also save operating costs.
We helped the client:
- Reduce the error rate in the production process
- Faster detection of contamination has already saved hundreds of thousands of crowns
- Simplify the calculation of the production price of products and therefore the sales margin
- Quickly prepare data and documents for official inspections, for example
What did they come to us with?
The client was faced with a complex and lengthy process of collecting information about production. At the same time, they had to strictly monitor quality and trace the origin of contamination, poor-quality product or ingredient as quickly as possible. A defective ingredient threatens the quality of the final product and the entire batch.
Unfortunately, 80% of the records were still in paper form and in the event of contamination, it was not immediately clear who had come into contact with the product. Data for hygiene was collected and compiled manually for several days. Some of the machines were not even capable of processing the data.
Client requirements
The client needed to create a comprehensive digital ecosystem. So that management could find out with just a few clicks what was happening in each part of the production and which employee was involved in each step.
He had a vision of ending manual data entry and creating a modern digital production that would minimize errors and speed up the entry, storage and retrieval of information. For internal quality control as well as for inspections by authorities and hygiene.
Our solution
As in any production, the production here was continuously modernized and included machines from different periods. With the most modern ones, there was no problem with obtaining data. We manufactured and installed our own sensors on older machines.
The centerpiece of the entire digitalization are tablets, in which employees monitor data and values from the machines and also record all their actions. They can immediately see everything that is happening in the dairy on the screen.
Employees enter what they are doing, what ingredient they are adding. Managers have access to this information. They can see what is happening, who is working with the ingredients and products. It is also easy to check the status of the machines. Everything is recorded, and the control takes place in real time.
Summary
Digitalization of production helped to meet the client’s goals: to increase production efficiency and speed up the detection of contamination. Thanks to digitalization of production, it is now detected immediately, and this change has already helped to save hundreds of thousands of crowns.
We have increased control and transparency of the production process. The result is an 85% lower number of poor-quality products and more satisfied customers. The possibility of human error is significantly lower.
The dairy can now accurately calculate the production cost of its products (e.g. cheese), which helps it in pricing and business decisions.
