To reduce the operatives to 2 and to ensue perfect product delivery to the boxing system.
A hydraulic driven laning system for aligning fish fingers that was so antiquated and inefficient that it required 12 operatives just to keep the system primed. Manual interventions meant that labour costs were high and product quality was being compromised.
Utilising the exact footprint of the existing line we introduced a highly efficient laning system which addressed the issues of:
- reduction in over feeding
- removal of double stacked product to ensure incorrectly formed products were remove
- fines and particles were eradicated from the product flow to enable operatives to add value by focusing on quality control and inspection.
The nature of the continuous production process meant that on occasions there was the potential for a bottle neck in the packing operation which would result in product wastage. Our solution was to introduce an emergency bypass mechanism to cold store the excess product, which could be metered controlled back into production to ensure no flood or overfill.
Factory efficiency with this new system increased from 52% to 94%. We have proposed additional solutions which could further benefit the company and would be likely to increase production efficiency even further if equipment up and down steam was replaced.
Spillage was reduced to near zero.
Full operation flexibility was achieved, keeping efficiencies of manufacture, frying and freezing at maximum capacity.