Food production quality and batch traceability system
The quality team sees the food batch research, used raw materials and deliveries. Once the problem is identified, it is possible to find the recipients and specify which stock to hold.
The result of the investigation, process verification and release decision are not always linked to a specific batch and its requirements. It takes quality assessment and the warehouse or planner can use an irrelevant batch fitness status.
How the solution works
- The production batch is assigned a valid specification and subject to checks.
- Samples, results and actual batches of raw materials and packaging are linked to the appropriate stage of the process.
- The deviation is passed to the assessor and the validated hold reaches the processes using the margin.
- An authorized professional makes a decision on release or follow-up with its basis.
- During the investigation or recall, the team locates the batches, quantities and recipients involved and checks what actions have already been taken.
Key challenges
- Quality control is disconnected from production
- Limited batch and component traceability
Solution capabilities
Specification and verification plan
A specific version of the batch includes process and laboratory checks, their methods and assessment requirements.
Sample-result relationship
The result has a sample, batch, survey and applied specification identifier.
batch Genealogy
Raw materials, recyclable material, packaging and the final product are linked by actual use.
Detention and release
The decision, its scope and its acceptance in the warehouse can be verified; the missing result is not considered positive.
Validity and restrictions on use
The approved term and quality status are passed to the stock process so that the earliest batch that loses its validity is selected according to established rules.
Determination of affected quantity and recipients
At the time of attempted or actual recall, the quantities produced, held, used, shipped and returned shall be checked and unexplained communications established.
Completion of non-compliance
The assessment of the cause, the approved action and proof of its execution are preserved.
Business context
- Quality control is disconnected from production
- The result of the investigation, process verification and release decision are not always linked to a specific batch and its requirements. It takes quality assessment and the warehouse or planner can use an irrelevant batch fitness status.
- Limited batch and component traceability
- It is not always possible to quickly restore the whole connection: the recipe, batches of raw materials, allergens, process records, packaging version and final batch. When a food safety issue arises, it takes time to determine the affected quantity, places of detention and recipients.
- The buyer receives the quality information of a specific supply
- The trader needs to know the origin, research results and remaining validity of the resulting batch. Linked data facilitates acceptance and response to a quality question. Once the problem is identified, it is possible to more accurately define the affected supplies and coordinate with the buyer.
Core features
- Specification and verification plan
- Sample-result relationship
- batch Genealogy
- Detention and release
- Validity and restrictions on use
- Determination of affected quantity and recipients
- Completion of non-compliance
Key integrations
- Food and beverage manufacturing execution system (MES)
- Actual batches of materials, operations, quantities produced and process checks.
- Laboratory system or equipment
- Sample and test result with unit of measurement and method relationship.
- Warehouse management system (WMS)
- Actual batch movements and confirmed admission of detention or release.
- Enterprise resource planning system (ERP)
- Purchase, Production and Sales Documents and Recipients.
- Recipe and Product Data Source
- The specification, labelling version and verification basis for the specific batch.
Potential impact (%)
The ranges indicate an illustrative relative change in the metric under the stated assumptions. Results depend on the starting position and actual use of the solution. Percentages for different metrics must not be added together.
The duration of determining the affected extent
12–36%Decreasing
This illustrative scenario assumes that 30-60% of manual data entry and handover work can be addressed. That share is assumed to fall by 40-60%. Company data is needed to verify both the addressable workload and the resulting change.
In test cancellations, the preparation time, fullness of established relationships and unexplained quantity are measured together.
Time of administration of batch release
12–36%Decreasing
This illustrative scenario assumes that 30-60% of manual data entry and handover work can be addressed. That share is assumed to fall by 40-60%. Company data is needed to verify both the addressable workload and the resulting change.
A distinction is made between the time of an employee's inspection and the length of investigation required and the expectation of an external response.
Conditional calculation scenarios. The assumptions have not been validated against client measurements.
When this solution is relevant
- In the trial recall, the recipients of the raw material are found, but not all of its path through return to process and produced batches.
- The laboratory result is obtained, but the packing or warehouse worker does not see an approved decision for a specific quantity.
Implementation requirements
For food traceability, the relationship between raw materials, batches produced and quantities shipped is aligned. Quality specialists define the course of detention, laboratory results and recall, and the warehouse system must follow approved movement restrictions.
Further development options
- A reconciliation of the recipient's cancellation confirmation and the amount returned
- Assessment of repeated supplier non-compliance