Digitizing Quality & Compliance Management Processes For a Lamb Meat Processing Plant
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
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.
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.
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.
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:
We identified client challenges, analyzed and prioritized issues, isolated critical areas, developed user personas, and mapped pain points for each persona to guide solution improvements.
Since we mutually decided to customize an existing product, we built wireframes for the additional features and got them approved before creating designs.
Our developers then incorporated the additional requirements of the client into the solution with the help of the wireframes and designs.
After integrating the solution with client data and requirements, we deployed it successfully and provided training to ensure the team could effectively utilize all system capabilities.
More than 300 forms were digitized, enabling task automation, scheduling, and assignment to QC technicians and production supervisors.
All documentation, including program manuals and SOPs, was digitized and linked to relevant task forms.
All five departments, including Animal Welfare, Fabrication, Case Ready, Shipping, and Receiving, were configured separately to enable structured management.
Four locations were configured with separate user management, enabling forms to be organized by location and allowing data sorting based on both date and location.
Missed tasks instantly appear on managers' dashboards, helping them identify causes, take corrective actions, and improve overall task accountability.
Preventive and corrective measures were automated through a rule-based violation system, enabling customized responses and proactive compliance management.
Active Directory integration simplified user access, reduced reliance on manual password management, and improved overall system usability.
Record reviews, pre-shipment reviews, and direct observations were automated with scheduling, maintaining accessible, traceable review histories.
The mobile application supported offline functionality, allowing workers to complete tasks without internet and sync data once connectivity resumed.
USDA personnel received dedicated web access to independently review compliance activities, reducing coordination efforts and improving inspection transparency.
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
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.
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.
Quality control managers and technicians have the option to use desktops or iPads to view and submit tasks, which offers them convenience.
Digitizing the system has greatly minimized human errors as well as the number of violations.
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.
The company ensures food safety and is following digital HACCP & CCP plans with a custom FSIS compliance management software.
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