Milk Powder Manufacturer Achieves Streamlined Production and Improved Quality Control with MES Implementation

IN A NUTSELL

A milk powder manufacturer in Malaysia implemented a Manufacturing Execution System (MES) to enhance the production efficiency and quality control of a new dryer line. The implementation aimed to reduce paper-based processes and data silos. Our solutions provided granular SAP integration, shop floor empowerment, quality assurance, customization, and scalability. Our technology helped the manufacturer to achieve better production efficiency and quality control of milk powder.

Challenge: Improve production efficiency and quality control for a new dryer line, while reducing paper-based processes and data silos.

The impact

25 work orders processed

304 mixes produced

2.93 million KGs of Wet Mix produced

700K KGs of Raw Material stock consumption posted

Getting into the details

About the client

Malaysia's dairy sector plays a key role in its agricultural economy. To cope with increasing demands and ensure sustainability, our customer wanted to improve production efficiency and quality control, especially for a new dryer line. This would help them enhance output, quality, and competitiveness in the market.

The problem

Improve production efficiency and quality control for a new dryer line, while reducing paper-based processes and data silos.

MES implementation for new dryer line

Individual batch mix and operation job management

Shopfloor automation for data capture

Paperless reports and dashboards

OEE (Overall Equipment Effectiveness) reports

Quality sample label printing and results recording

Automatic data transfer to SAP

MINDSPRINT's Solution:

01 Integration Expertise:

Granular SAP Integration: MINDSPRINT went beyond simply connecting SAP and MES. We meticulously split SAP process orders into individual jobs for each batch mix and operation, ensuring precise tracking and accountability. This level of detail empowers production managers to analyze performance at the micro-level, optimizing each step of the process.
Data Silos Smashed: By integrating MES with the automation layer, MINDSPRINT broke down data silos, allowing real-time PLC data to flow seamlessly into the MES system. This eliminates manual data entry and potential errors, resulting in a single source of truth for production data.

02 Shopfloor Empowerment:

Handheld Power: Equipping operators with handheld devices empowered them to take ownership of data capture. From declaring material movements to reporting quality checks, these devices streamline workflows, boost data accuracy, and free up managers to focus on strategic tasks.
Automation Advantage: Automatic work order startup provided immediate visibility into line status, enabling proactive responses to potential issues. This real-time feedback loop empowers supervisors to react swiftly and efficiently, minimizing downtime and maximizing production output.

03 Quality Comes First:

Labeling Innovation: Procuring dedicated label printers streamlines sample labeling, eliminating handwritten errors and ensuring proper identification throughout the process. This enhances traceability and accountability, crucial for maintaining high-quality standards.
QR Code Efficiency: Implementing QR code scanning on sample labels simplifies result recording. Operators can quickly and accurately log data, reducing potential errors and expediting quality analysis. This fosters a data-driven approach to quality management, allowing for swift identification and correction of any deviations from standards.

04 Beyond the Basics:

Customization is Key: MINDSPRINT's solution wasn't a one-size-fits-all approach. They tailored the MES implementation to the specific needs and workflows of the milk powder manufacturer, ensuring optimal fit and maximum impact.
Scalability in Mind: The chosen system provided the flexibility to scale alongside the manufacturer's future growth. This foresight paves the way for the seamless integration of additional production lines or equipment without major disruptions.

Enhanced operational agility: Real-time data and visibility enable quick adjustments to optimize production based on current conditions.
Improved decision-making: Data-driven insights from OEE reports and individual batch analysis equip management with actionable information for strategic planning and continuous improvement.
Elevated compliance: Streamlined paperless workflows and automated data transfer to SAP ensure adherence to regulatory requirements and best practices.