A Leading Lamb Processing Plant – EcoDocs

Digitizing Quality & Compliance Management Processes For a Lamb Meat Processing Plant

Problem

The company wanted to improve operational efficiencies by eliminating paper-based reviews & forms as it was time-consuming, not actionable and delayed incident reporting that risked compliance deviations

Need

They needed a compliance management solution that could help them acquire, organize, monitor and use day-to-day records to ensure USDA standards compliance from their desks & smart devices.

Solution

The web and iPad application automated & digitized Preshipment, record reviews & other forms to save time and take preventive measures to violations with automatic reminders & alerts. The meat processing plant can have a consolidated view of tasks and performance of all 4 locations in real time.

About

The Comapny

A renowned market leader in the meatpacking industry with more than 1000 family ranch partners, the company is a lamb processing plant spread across four locations in the United States. Having recently unveiled the “greenest” lamb plant in the United States, it is known for being extremely vigilant about animal welfare, managing data efficiently, and maintaining traceability.

Understanding the Challenge

Manual Processes Causing Inefficiencies

With ever-growing business, manual processes became challenging for the lamb processing plant. Conventional ways of keeping records were becoming increasingly difficult to manage, track, and maintain. This is because of several reasons:

Managing processes using paper-based forms was difficult, and there were higher chances of human error.
Managers had to conduct, track, and maintain daily, weekly, monthly, and annual reviews and forms manually, which wasted a lot of time.
Reviews such as record reviews, and pre-shipment reviews were taking too much time and effort. This made decision-making extremely slow.
If a USDA compliance officer asked to see submitted tasks or reviews, the process would be long and cumbersome because QC techs would have to dig into old paper-based data to find records.
It was difficult to track violations because of manual processes.
Having manual HACCP plans and following SOPs of each dept. like animal welfare, fabrication, case ready, shipping & receiving was a tough task.

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Why Digital Transformation is
Important?

Successful meat producers and processors in the 21st century need to be extremely productive, efficient, and resilient if they are to stand the test of digital, the data driven, revolution in the sector. It plays a pivotal role in driving optimum outcomes by controlling and managing data across the value chain.

Building The Solution

Automating Work Orders and Digitizing Workflows

Folio3 helped eliminate the paper-based processes and digitized the whole process and system for the client. The digital transformation not only helped save time, but also solved the data accuracy and transparency issues. Our FSIS food safety and compliance management solution centred around digitizing their location, quality, and compliance management with USDA regulations.

Our Approach

Understanding The User Journey
First, we identified the challenges being faced by the client. We dissected the problems, prioritized them, and identified the critical parts. We created user personas and identified the pain points for each persona.
Building Wireframes & Designs
Since we mutually decided to customize an existing product, we built wireframes for the additional features and got them approved before creating designs.
Customizing The Existing Solution
Our developers then incorporated the additional requirements of the client into the solution with the help of the wireframes and designs.
Deployment & Training
After synchronizing and integrating the solution with the client’s data and requirements, the solution was implemented and training was offered, so the team could leverage it to the fullest.

The Solution

The Resulting Transformation

Increased Productivity & Efficiency

Folio3 automated the entire process for the client with a continuous support system and facilitated them in the management and tracking of their daily tasks. Tasks were scheduled automatically, which helped them comply with the standard procedures.

All four locations were configured, and the entire process was streamlined by location and user roles, which helped them organize their workflows

Digitized different 300 forms

19000 forms have been filled out in just the first 3 months of implementation out of the 300 forms that were digitized, which means 19000 tasks have been completed and documented.

Increased productivity and efficiency

The client has witnessed increased productivity and efficiency. Tasks are not missed, and workers can concentrate more on the task rather than juggling paper-based forms.

Made processes convenient

Quality control managers and technicians have the option to use desktops or iPads to view and submit tasks, which offers them convenience.

Minimized human errors

Digitizing the system has greatly minimized human errors as well as the number of violations.

Increased transparency

There is increased transparency in the entire process. The directors and management heads have access to data for all locations, and they are able to review it in real-time.

FSIS compliance is much easier

The company ensures food safety and is following digital HACCP & CCP plans with a custom FSIS compliance management software.