CASE STUDY:
ANZCO
MANUAL BLAST FREEZING OPTIMISATION
OVERVIEW
ANZCO Foods Canterbury is a multispecies meat processing facility. Annual volumes (2015/16 season) were in excess of 53,000t processed of which approximately 40,000t is frozen product. This translates to a throughput of over 2 million frozen product cartons that has to be handled through the onsite Distribution Centre – blast freezing, storage and despatch.
The onsite manual blast freezing utilisation was not efficient resulting in large volumes being sent for offsite blasting. The calculated average utilisation of the manual blast freezers was 55% for the 2015/16 season.
CAPABILITIES DEPLOYED
1. Process layout optimisation
Frozen carton ex factory through manual blasts and ex DC mapped with DC team. Based on this the constraints were identified. Possible solutions were evaluated.
2. Modelling
Based on Sales forecast for next 3 years the flow of cartons through the proposed solution was modelled and performance targets set for the next 3 seasons in conjunction with team members.
3. Visual Management
In order to ensure sustainability the DC was demarcated (pallet store) in accordance with the proposed solution. Team members were trained in new layout and process flow.
4. Short Interval Management
Daily performance measurement metrics were visualised and a review
RESULTS
Associated with the increased manual blast utilisation a better operational practice was established (e.g. reduction of ‘open blast door’ time due to an improved flow of material in the DC). This has led to a reduction in energy consumption and less time spent ‘digging’ for product.
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