JealsaDriving Productivity Through More Effective Operations Management

Case Study

Solution delivered by Parsec Certified Partner

01 Jealsa Driving Productivity Improvements

Utilized TrakSYSTM Features & Functions

Food & Beverage Industry

With a state-of-the-art facility already running, Jealsa needed a world-class system that could manage all aspects of their enterprise while keeping costs down and maintaining the high level of quality that Jealsa has become known for worldwide.

Job/WIP Management

Labor Management

ERP Integration

Electronic Forms

Historian

Performance Management

Traceability & Genealogy

Material Management

Messaging & Notification

Quality & SPC

02 Jealsa Driving Productivity Improvements

Without a real-time operations

management system in place,

Jealsa had no efficient way to

utilize existing capacity to its

fullest potential.

03 Jealsa Driving Productivity Improvements

The Jealsa Group is a Spanish food company with more than 50 years of experience dedicated originally to the manufacture and marketing of canned fish and seafood.

In 1958 an enterprising businessman, Mr. Jesús Alonso Fernández, created the canning company that bore his name, and in 1974 became a public limited company with the name of Jesús Alonso, S.A. (Jealsa). The factory in Boiro is the central headquarters and is considered by many experts as one of the most modern in the world. Here the elaborate process of canned tuna is centralized, having the principle quality certificates and complying with the international sustainability standards. Nowadays, thanks to the commitment to diversification and innovation, Jealsa has become the top manufacturer of canned food of Spain and second in Europe.1

With a world-class factory, Jealsa has always been on the cutting edge of production, and has been for many decades. Creating the first easy-open canned products in Spain, and the first to offer healthier options by including olive oil in all of its products (versus vegetable oil, which is the cheaper standard).

Jealsa has been committed to producing healthy foods and introducing new technologies such as; early adoption of aluminum cans, and innovative pressure cooking process to provide great value to the consumers. Today, Jealsa enjoys a growing global presence.

With growing market share, and demand for added capacity, it was imperative to improve operational efficiency. However, with disparate systems—production and business— it was difficult to collect, analyze, and use data to achieve this goal.

Company Overview

04 Jealsa Driving Productivity Improvements

“Our project had very ambitious goals: improving manufacturing productivity, product tracking, and integration with SAP. TrakSYS™ rapidly helped us to better understand the productivity of our assets, standardize plant floor processes, and improve operations. However, one of the most significant accomplishments was closing the gap between plant floor and business systems in real-time. TrakSYS™ was instrumental in making this happen.”

-Alejandro DopazoProduction & Process Leader

05 Jealsa Driving Productivity Improvements

TrakSYSTM Solution Architecture

• TrakSYS™ was deployed on one server dedicated to the Application, Database, and Web.

• 4 cleaning lines, 8 filling and sealing lines, 8 sterilizers, 5 packaging and case packing lines.

• Real-time information exchange with process automation systems and ERP (SAP).

• Plant-wide user workstations to view production and performance information via standard browser technology.

• TrakSYS™ collects the ID of each pallet introduced in each sterilizer, calculates the sterilization cycle time, collects the temperature for the sterilization cycle and generates alarms when a rule is violated. Advanced HACCP process with bottleneck analysis and control features.

• TrakSYS™ is collecting data from a SPC solution

(out of TrakSYS™) tracking weights in the packing process. TrakSYS™ collects and shows the average weight vs the target.

TrakSYS™ was selected because it met all the project requirements. Specifically, Jealsa chose TrakSYS™ because:

• Open and configurable application

• Ease of configuration (without the need for programming and custom development)

• Powerful, expandable, fast to deploy, and very economical

• Support

Corporate Users

Plant Floor Users

Dynamic Displays

Plant Floor Users

Cleaning

Firewall

Plant Floor Users

Plant Floor Users

Packaging

Track & TraceCanning Machine

ERP

Figure 1 - Jealsa TrakSYS™ Architecture

Figure 2 - Jealsa TrakSYS™ Screens

Informing and Empowering

The TrakSYS™ user interfaces were designed to fit the specific roles and needs of the users across the manufacturing operation.

06 Jealsa Driving Productivity Improvements

07 Jealsa Driving Productivity Improvements

TrakSYSTM Solutions Results

The following results and related benefits were realized through collaborative engagement and the effective use of the TrakSYS™-based solution:

WorkflowManagement

Increased Productivity

TrackingAccuracy Improved

RefinedProduction Planning through Integration of TrakSYS™ & SAP

15%OEE Improvement in

3 Months

PreventFuture Problems using Root Cause

Analysis

EngagedOperators in both Commitment and

Improvement

200,000Additional Cans

per Day are Now Available

10%Reduction in Cost of

Goods Sold

With TrakSYS™, Jealsa gained 15%

improvement in OEE in three

months through bottleneck analysis,

identification of preventable root

causes, and implementation of

corrective actions.

Results

There were several other functional benefits that were quickly realized after the deployment of TrakSYS™:

• Achieved a 20 point OEE improvement in packaging.

• Accurately and consistently identified the root causes of productivity losses.

• Established visual management for operational productivity.

• 10% increase in packaging capacity.

• Quality and performance issues can now be compared and reviewed against individual suppliers of raw materials.

• A plant-wide productivity improvement of 15%.

• 34% increase in capacity in sterilization areas.

• 15 point OEE improvement in packing and sealing areas.

Achieved TrakSYS™ Solution Benefits

TM

Copyright Parsec Automation Corp. 2016 All trademarks are the property of their respective owners

Parsec is the developer of TrakSYS™, a proven operations management software application and solution platform designed to significantly improve manufacturing processes. Parsec is committed to providing best-in-class products and solutions to our worldwide community of clients to assist them in optimizing their manufacturing operations. There are thousands of TrakSYS™ licenses in use around the globe in a wide variety of Industries.

TrakSYS™ helps manufacturers to maximize asset utilization and efficiency, increase capacity with no new capital equipment, reduce production costs, decrease lead time, and improve profitability. For more information about Parsec and TrakSYS™, please visit the corporate website at www.parsec-corp.com.

About Parsec

1. Jealsa | About us. (n.d.). Retrieved January 13, 2016, from http://www.jealsa.com/en/inicio-ingl/about-us/

Sources