For safety and quality, it’s imperative that the correct cleaning between products is done each and every time. While doing the longest and most thorough clean between each product guarantees safety and quality, it comes as the cost of significantly lower output and increased negative environmental impact. Manufacturers need a way to systematically capture safety and quality rules to automatically guide production plans and schedules with guaranteed safety and quality, greater output, and lower environmental impact.
SITUATION: A flavors manufacturer for major food and beverage companies has 6 blenders and order visibility 3 weeks into the future. So long as the previous and next product are not exactly the same, the longest and most thorough multi-hour clean is conducted to guarantee safety and quality. 50% or more of the available production time is used for cleaning.
CHALLENGE: The quality team knows that based on certain product characteristics, such as flavor or color, a much shorter clean can be done while still ensuring safety and quality standards. How can these complex safety and quality rules be captured, while also considering machine capacities and due dates, to then generate production schedules with signficiantly shorter cleaning times?
SOLUTION: Zeno’s custom-built graph data structures makes it possible to capture unique product characteristics and their relationships to then construct any level of complex safety and quality rules. The quality team has direct access to these rules which can be amended as new findings from testing are discovered and new products are added. Systematically codifying these rules means production schedules can be generated with a variety of possible cleanings to decrease cleaning times dramatically.