Granarolo chooses sedApta

The Granarolo Group represents the most important Italian milk supply chain, directly involving producers in a cooperative form. It brings together over 600 dairy farmers, an organization for the collection of raw materials at the cowshed with approximately 100 tankers, and 720 distribution vehicles, which move 850 thousand tons per year. These vehicles serve around 50 thousand points of sale daily, where approximately 20 million Italian families purchase Granarolo products. The Group’s mission abroad is to export the tradition of Made in Italy products.

The three main business areas of Granarolo revolve around fresh milk:

  • Milk and Cream
  • Cheese and Butter
  • Yogurt and Snack

Objectives

The project, structured with MES (Manufacturing Execution System) software modules from the sedApta suite, was aimed at achieving the following main objectives: flexibility and optimization of production plans; precise management of order progress; traceability and traceability of raw materials, semi-finished, and finished products; support for quality process control; elimination of paper documents; integration of systems and machines for the direct acquisition of significant production and process data; an opportunity for training in a new approach to the management and execution of production processes.

Solution

The solution, structured around the sedApta software modules: Shop Floor Monitor (MES), Check List, Tracciabilità, Factory Scheduling (production plan scheduler), and DAS (IIoT Edge interface and acquisition of plant and machine data), envisions an integrated system on a LAN backbone. This system encompasses different levels of expertise and functionality, marked by an efficient flow and sharing of data, benefiting safety, continuity, and control and management of production progress.

Benefits

  • flexible management of production plans, optimized in sequences, production times and evaluation of actual loads, with reference to the relevant constraints and optimization matrices.
  • efficient management of the progress and control of work orders and quality procedures, as well as the availability of the final data shared with the company’s systems to support the conformity of the batches produced, the safety and quality of the finished product and continuous improvement.
  • paperless management of the progress of work orders and computerized checklists, for effective consultation and analysis of both quality and production historical data.
  • the traceability and retractability of material flows (batches, quantities, etc.) of the fully automatic mix preparation phases with the management of intermediate batches for each transfer, loading and unloading operation of the (liquid) material; the subsequent phases up to the packaging and palletizing islands, effectively supported by reports from the production progress data and check lists.
  • the availability of objective and timely data acquired from the field, through direct interface with machines and production facilities.
  • real-time and historical visibility of the status and trend of production processes, extended to all the skills involved (management, production manager, quality manager, operators, maintenance staff, etc.) allowing specific analyses and collaborative and shared interventions for possible corrective and improvement actions.
  • raising awareness and involvement of all operational and functional levels in the new operational model of production planning and management.

 

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