Technical and economical aspects of maintenance in poultry processing

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Presentation

• Technical and economical aspects of maintenance
  in poultry processing
• Henk Hupkes
• Bart Kunst
• Meyn Food Processing Technology BV
• NL-1511 AE Oostzaan
• The Netherlands

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(No Transcript)
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• 1. Introduction
• 2. Slaughter process
• 3. Quality
• 4. Product safety
• 5. Optimization
• 6. Slaughter technology
• 7. Maintenance
• 8. Maintenance contracts
• 9. Summary

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Market developments and trends World
chickenmeat consumption (kg/person/year)
Source WATT
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Market developments and trends Regional chicken
meat production 1996-2006
sourceWatt
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Market developments and trends Brazil
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Market developments and trends Increasing
markets - Others
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2. Slaughter process
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Slaughter process
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Slaughter process
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Quality

• Always specify
• pH, Colour, Sensitiveness, Price, Weight,
  Packing, Animal welfare, etc, etc

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Product safety

• Essential (EC) 178/2002
• Guaranty (EC) 852/2004
• (EC) 853/2004 Absence
• (EC) 854/2004 Health risks

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Improvement or Optimization
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Electrical stimulation
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Electrical stimulation
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Electrical stimulation
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Camera Systems
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Camera Systems
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SMARTDynamic Weight and Quality Check
correct product
Weight
Quality
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Physic Cut-up System
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Physic Cut-up System
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Compact cut-up system

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Compact cut-up system

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Rapid HQ Breast deboner
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Rapid HQ Breast deboner
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Hierarchy in controls
Control
Monitoring
Primary Processing
Order Preparation
Expedition
Production

• Order picking
• Despatch

• Packing
• Labelling
• Pricing

• Distribution
• Cut up
• Deboning
• Transport

• Arrival
• Killing
• Evisceration
• Chilling

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Wall to wall solutions
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Traceability Genealogy
Which products have been made by using which
flock?
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Tracking Genealogy ModuleTracking
Database
Lot activation
Quality grading
Quality grading
INTERFACES
Tracker
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Animal welfare
Grower
Quality grading
Transport
Grower inspection support module
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Installed Base Management
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Installed Base Management Strategy
Make Money
Financial perspective
Grow Volume
Increase Profit margin
Productive Installed Base
Customer perspective
Increased Availability, Performance and Quality
Provide, Maintain and Operate well
Competent and sufficient staff
People and skills
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Installed Base Management Challenge
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Cost of Maintenance (Maintenance point of view)

• Material
• Labour/Resources
• Warehousing
• Logistics
• Tools
• Production time loss
• (maintenance time frame)

Costs
Maintenance Effort
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Cost of Maintenance(Production point of view)

• Downtime Loss
• Speed Loss
• Quality Loss

Costs
Maintenance Effort
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Cost of Maintenance The Six Big Losses
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Cost of Maintenance (total)

• The idea is to optimise the
• total cost by using
• the best combination
• of maintenance strategies

Costs
Maintenance Effort
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Maintenance versus Operating CostMantenimiento
contra gastos de operativo
Minimum operating costs (production
maintenance) Gastos de operativo
mínimo (producción y mantenimiento)
Maintenance activities (frequency,
scope) Actividades de mantenimiento (frecuencia,
alcance)
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Maintenance tactics

• Different maintenance tactics
• Run to failure.
• Usage based maintenance.
• Condition based maintenance.
• Design improvement maintenance.

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Different possible tactics

• Run-to-failure
• The Maintenance Tactic whereby equipment is
  allowed to operate until failure.

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Different possible tactics

• Usage-based maintenance
• The Maintenance Tactic whereby corrective
  maintenance activities are executed at
  predetermined intervals of usage (days, mileage,
  tonnage, hours, batches, events etc.).

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Different possible tactics

• Condition-based maintenance
• The Maintenance Tactic whereby inspections or
  tests are done to verify the condition of the
  equipment, which will then initiate corrective
  follow-up maintenance, if the condition is
  approaching an unacceptable condition. It is
  predictive in nature and the purpose is to
  prevent unacceptable consequences before they
  occur by monitoring some characteristic of the
  failure.

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Different possible tactics

• Design Improvement Maintenance
• The Maintenance Tactic whereby equipment is
  modified to improve performance, or to eliminate
  or reduce the consequences of failures.

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Cost of Maintenance - Optimum Mix
Total Maintenance
Any Tactic is by definition better or equal than
a Breakdown approach!
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Maintenance Maturity
Maturity
Stage 5
Reduction
Improvement
Stage 4
Prevention
Stage 3
Stabilisation
Stage 2
Stage 1
Firefighting
Time
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Stage 1 - Firefighting
High
Med.
Low
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Stage 2 - Stabilization
High
Med.
Low
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Stage 3 - Prevention
High
Med.
Low
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Stage 4 - Improvement
High
Med.
Low
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Stage 5 - Reduction
High
Med.
Low
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Optimum Maintenance Mix
High
Med.
Low
Condition Based Maintenance
Fixed-interval Maintenance
Maintenance Reduction
Breakdown Maintenance
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The Maintenance ChallengeFinding the optimum
between knowledge cost

• Maintenance is a balance between Strategic
  Decisions

higher maintenance costs less production losses
less maintenance costs higher production losses

• An ideal mix is often found in a core,
  well-trained in-house staff with external
  specialists for major overhauls and process
  improvement actions.

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Practical maintenance case for a Rapid HQ Breast
deboner
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Case Rapid HQ deboning system

• 1 fully automated production line.
• 9.500 BPH.
• 152.000 BPD (Project 250.000 BPD).
• Cut up/deboning 120.000 breast caps per day.
• 2x Rapid HQ installed end 2007.
• Maintenance agreement 1 year Rapid HQ.
• Monthly support visits.

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Case Customermaintenance challenges 2009

• After 1 year experience with Rapid HQ
• How to deal with less maintenance budget?
• Continue with the maintenance agreement?
• How do we achieve a structured maintenance
  approach and avoid unpredictable and expensive
  maintenance actions?
• Do we have enough skilled resources for
  maintenance?
• How do we keep the high performance of the
  machines?

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The Maintenance Challenge Current situation

• Decisions taken by Customer
• Not to continue with maintenance agreement and
  monthly support visits.
• Reduction of the maintenance budget.
• Use of maintenance staff Customer for
  maintenance.
• 5 months later
• 2 - 3 less yield on the Rapid HQs.
• 27.000 euro/week loss (2 Rapid HQs).
• 1.350.000 euro/year loss (50 production weeks).

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The Maintenance ChallengeResults

• Define the best combination of maintenance
  tactics (costs).
• Well trained in-house staff for the more simple
  or conditioned base maintenance tasks, with
  minimum impact on the performance/productivity.
• Outsourcing of major maintenance tasks (OEM
  specialists) with high impact on the
  performance/productivity (in- outsourcing
  knowledge).
• Shared responsibility on preventive maintenance
  (partnership).
• Monthly support visits for adjustments
  (fine-tuning), process improvement actions and
  instructions for operator and maintenance crew.
• Optimized yield and availability.

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Maintenance agreement options

• Option A
• Preventive Maintenance
• 1st 180 machine
• carcass brush
• de-skinner
• half fillets cutter
• tables
• product carriers
• static tenderloin harvester

• Option B
• Carriers Excluded
• 1st 180 machine
• carcass brush
• de-skinner
• half fillets cutter
• tables
• static tenderloin harvester

• Option C
• All CBM excluded
• 1st 180 machine
• de-skinner

- carcass brush - half fillets cutter - tables -
product carriers - static tenderloin harvester
- product carriers
Daily-, Weekly-, Monthly- Corrective
maintenance tasks Safety- Initial Stock
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What does a service agreement buy you?
Availability
Performance
Quality
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Maintenance Agreement

• What does maintenance agreement buy you?
• keeps equipment running (Availability)
• enhance equipment reliability (Availability)
• enhance equipment speed (Performance)
• enhance equipment precision (Quality)
• enhance equipment safety

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Service Agreements
Maintenance Agreement
Parts Supply Agreement
Maintenance support Agreement
Service Agreements
Service Level
Inspection Agreement
Help Desk Agreement
Basic Service Products
Basic Service
Service Policy
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Service levels
Maintenance Agreement
Supply of Total Service
Parts Supply Agreement
Supply of parts
Maintenance support Agreement
Allocation of specialists
Service level
Inspection Agreement
Periodical inspections with recommended actions
Help Desk Agreement
Call centre support
Basic Service Products
Parts, specialists, training
Service Policy
Helpdesk, ict systems
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Scope of supply Maintenance Agreement

• Staff to execute (Service Specialists) Preventive
  Maintenance
• Staff to manage (Service Project Manager)
  Preventive Maintenance
• Wear Tear Parts

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M.A.s cost optimum
Minimum operational costs (production
maintenance costs)
Maintenance costs (o.a. spares)
Production costs (o.a. downtime)
Maintenance activities (frequency, magnitude)
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M.A.s result optimum
Maximum result (revenues - operational costs)
Result
Revenues (o.a. yield)
Operational costs
Maintenance activities (frequency, magnitude)
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Summary
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Meyn do Brasil Ltda. Av. Selma Parada,
201 Galleria Office Park Edificio 3, Conj.
333 Campinas SP Brasil CEP 13091-901 Tel 55
19 3707 5380 Fax [phone] Contact Mr.
Fabiano Benvenutti

• Meyn Food Processing Technology B.V.
• P.O. Box 16
• 1510 AA Oostzaan
• Noordeinde 68
• 1511 AE Oostzaan
• The Netherlands
• Tel [phone]
• Fax [phone]
• Internet www.meyn.nl
• E-mail info_at_meyn.nl
• Contact Mr. Bart Kunst