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The automation of the meat processing plant «Bakht» in Uzbekistan

Customer
Bakht
Project manager on the customer side
Elbek Musinov
Deputy Director for Financial Affairs
IT Provider
First Bit
Year of project completion
2022
Project timeline
November, 2019 - October, 2022
Project scope
105 automated workstations
Goals
  1. Automate the processes of collecting and processing real-time production and technological information directly at its point of origin and transmitting it in online mode to the accounting system.
  2. Ensure the ability to control inventory (materials, goods in process, finished goods) on external and internal warehouses.
  3. Enable quality control of finished product manufacturing to detect defects and maintain consistent quality parameters.
  4. Implement data collection on staff productivity (both individual employees and teams/shifts) for piece-rate wage calculation.
  5. Automate real-time accounting to enhance the speed of order fulfillment and delivery of finished products to customers.

Project Results
  1. The volume of shipped products has increased, order assembly time has been reduced by 2.5 times due to the automation and equipment of the newly constructed finished product warehouse.
  2. Human factor has been minimized.
  3. Employee productivity now is monitored.
  4. Real-time tracking of material movements, production operations and inventory control across warehouses and production areas has been implemented.
  5. Recipe control is ensured when assembling meat and spice kits.
  6. Automation of 33 unique control points, such as Spice Assembly, Raw Material Reception, Customer Order Assembly, etc.
  7. Workstations for shop floor supervisors have been automated.
  8. Shipped product volumes have increased from 13 to 45 tons (almost 350% growth).

The uniqueness of the project

The uniqueness of the project primarily lies in the fact that the customer's company is located in Uzbekistan. Nevertheless, in order to address the needs the customer chose Russian software. Another distinctive feature is the presence of four loading points and the absence of an initial inventory of finished products at the customer's company. Our specialists in collaboration with the manufacturer installed a gravity warehouse in the designated space, placed and equipped control points with printers and barcode scanners, set up weighing equipment, and documented new business processes for each control point in the WMS. As a result, the customer obtained a solution to their issues and an automated working warehouse for finished products.

Used software
Scales, scanners, label printers, industrial PCs, data collection terminals
Difficulty of implementation

The project's complexity stemmed from the fact that the enterprise had significant overlap in material flows (raw materials, finished products, packaging materials, etc.), making the production process and accounting within the system more intricate. This intricate network of material flows required a sophisticated and well-coordinated automation solution to ensure efficient and accurate tracking of inventory, production, and other related processes.

Project Description

The meat processing plant "Bakht" began its operations in Uzbekistan in 1996. Since then, its premises have continuously expanded, accommodating new workshops, irrigated land, and even ponds for carp breeding. Inspired by its successful development and the picturesque nature of the Samarkand region, the organization plans to further increase its production capacity and expand its product exports.

Before the project's launch, the company managed its managerial, operational and production accounting using Excel, SalesDoctor, and 1C:Accounting. Proper control of inventory (materials, goods in process) was lacking, and there was no understanding of the stock levels in external warehouses, making it challenging to monitor product shelf life. Furthermore, the company's business activity involved purchasing goods in large quantities, which posed risks of having expired products, potentially resulting in financial losses. Tracking the movement and receipt of goods was initially done in 1C:Accounting, with data then being exported to Excel and reconciled through manual inventory checks on the warehouse floor. Due to these issues, the company's management decided to automate operational accounting.

Before the project began, the customer did not have a clear understanding of which software product to install. Specialists from the company First.Bit conducted an analysis of the enterprise's business processes, identified problem areas, and proposed the implementation of the "1C: Meat Processing MES Module for 1C: ERP" program. This choice was made because it aligns with the company's specific needs and meets the customer's current requirements.

Within the project, the following areas have been automated: Accounting, including Production Operations.

Industry-Specific Features:

  • Managing data on product composition and structure, including recipes.
  • Managing data on production technology (routing sheets).
  • Cost accounting for production.
  • Material demand planning.
  • Shop-floor (shift) production planning.
  • Production dispatching at the shop level.
  • Production order tracking.
The following areas of the production processes have also been automated:

  1. Automation of raw material reception in storage refrigerators from external suppliers, including labeling and shelf life control.
  2. Organization of spice reception with labeling from suppliers, ensuring packaging traceability.
  3. Receipt of carcass meat.
  4. Inventory management at the processing stage with control over incoming raw materials and the percentage of finished product yield.
  5. Issuing tasks for assembling spice kits, ensuring correct assembly and component traceability.
  6. Automation of the packaging area for minced meat production, using automated workplace Packaging based on production plans.
  7. Implementation of packaging materials at the forming and packaging sections accjrding to the volume of products produced.
  8. Introduction of a workstation for heat processor which allows to control the time semi-finished products spend in the area and thermal operations.
  9. Automation of monitoring excess time of semi-finished products on production sections.
  10. Automation of inventory management at vacuuming and cutting, packaging, storage in the finished product warehouse, and shipping sections.
  11. Automation of the production areas for pates, dumplings, and cutlets.
  12. Automation of the movement and shipment processes for frozen products, sausage products, and raw products in the finished product warehouse.
  13. Creation of a concept for introducing technological/technical innovations and production processes for the finished product warehouse.
  14. Development of a concept for aligning residuals levels in production and accounting systems.

During the project, work was also carried out to adapt the standard solution. As part of the project, specialists from First Bit provided consulting services for optimizing the production process, performed tasks related to the adaptation and technical implementation of industry-specific (meat processing) and enterprise-specific accounting tasks. For example,

  • Receiving spices from suppliers with barcodes containing product information, expiration dates, and unique batch numbers.
  • Production and operational accounting across multiple organizations.
  • Customizing the inventory workstation to reflect inventory data in the ERP and MES systems.
  • Tracking spices in minimum quantities (packages) with the ability to break down pallets/boxes and ensure traceability to the parent container.
  • Group reception with subdivision into packages and assignment of serial numbers.
  • Customizations of the Raw Material Assembly Workstation to improve usability during salting operations.
  • Enhancements to the Spice Workstation to allow the use of multiple source batches for components and the ability to distribute sets into different containers.
  • Enhancements to the mobile application for working with order-based warehouses.
  • Customizing the workstation to account for employee productivity.
  • Transmitting MES documents to the ERP system to reflect actual production data in the accounting system.
  • Integration in the finished product warehouse area with the WMS, MES, and ERP systems.

Project geography

Uzbekistan, Samarkand

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