Industry: Food & Beverages
In the delicatessen industry, smooth production and logistics processes are essential: Raw materials and ingredients from the vendors must arrive on demand and in time so they can be processed and delivered to the customers as quickly as possible. Furthermore, end-to-end traceability must be ensured. Kugler Feinkost GmbH manages all of this with the CSB-System.
“Since 1995, the software has supported and optimized our processes. It enables us to produce and deliver our goods in a fast, reliable and flexible manner. If you place your orders before noon, you can receive your goods on the next day,” says Managing Director Oliver Kugler. The raw materials for production are ordered from the vendors directly via the software. The staff in receiving can always retrieve any information related to the orders so they can access the details when the ordered goods are coming in. In addition to delivery quantities and weight, the system stores quality queries requiring input upon entry of the goods in the system. Such quality tests comprise temperature, remaining durability and other item-specific test parameters. The system clearly indicates every step of the tests. With so-called “escalation levels”, it ensures that all parameters are strictly adhered to. In case the permitted temperature of the incoming raw material is exceeded, for example, the employees in Quality Assurance automatically receive an e-mail and the goods are blocked. The weight is strictly controlled too: “If we find in receiving that only 480 kg of the ordered 500 kg raw material were delivered, only the delivered quantity will be paid – without requiring manual intervention. The weight data is immediately transferred to invoicing,” Managing Director Gerhard Schrittenlocher explains.
Many of the vendors label their goods with EAN-128 codes, which can be read in with mobile data capture devices. This minimizes time-consuming input of data, including traceability data, via the keyboards.
Optimized material usage
During batch processing, the different raw materials are weighed as stipulated in the production schedule and recipes. For every product group, dedicated IT workstations with integrated scales, so-called CSB-Racks, were installed where the staff processes the single production batches. The software precisely indicates for each recipe which raw materials may be used, and which quantities. If a product exceeds the defined weight tolerances, the batch is automatically blocked and discharged from production. Such strict recipe requirements secure constantly high quality as well as optimal use of materials. Moreover, the CSB-Racks facilitate efficient processing of the scheduled work steps in accordance with the requirements. The user must confirm every procedure on the screen; otherwise, it is not possible to proceed.
Traceability guaranteed
The completed batches move on to six filling lines where the weight of the goods is re-checked. The system automatically generates corresponding labels and effects the inventory posting. In addition to the details required by the new food information regulation with regard to nutritional values, allergens etc., every packaging label indicates an EAN-128 code as well as the lot number. Every product can thus be split into its raw material components to allow for seamless tracing. “We offer our customers full end-to-end tracing. The data captured in batch processing is included in the code, scanned in picking and passed on to the customer,” says Gerhard Schrittenlocher.
Gross margins at the push of the button
Kugler successfully balances professional production of large quantities and flexible manufacturing of tailor-made goods, also thanks to the modern information technology. “Our distinct profile in terms of on-demand production of daily fresh convenience products only works if the IT system is highly integrated and supports all processes,” says Oliver Kugler.
Moreover, the system provides fast and accurate controlling data to the day, at the push of a button. The delicatessen supplier can calculate the gross margin already during order entry. “When billing the customers, the daily data from purchasing are updated in conditions and background statistics so we can establish, at any time, 100% precise marginal costing per day for every product and every customer. The same data is also applied as a basis for controlling sales. This helps us in making the right decisions”, says Oliver Kugler.
