Anglo Beef Processors Ltd

Anglo Beef Processors Ltd

Case StudyOperatorCase StudyOperator

November 2006davebarratt@abpltd.com

Who are ABP?Who are ABP?

Fresh Beef & LambProcessor & Retail Packing

Fresh Beef & LambProcessor & Retail Packing

Frozen Meat / Products & Burgers

Largest Own Label Burger Producer

Frozen Meat / Products & Burgers

Largest Own Label Burger Producer

Freshlink FoodsFreshlink Foods

Fresh Beef & LambProcessor & Retail Packing

Fresh Beef & LambProcessor & Retail Packing

Dedicated Frozen Burger Production

Dedicated Frozen Burger Production

R.O.I.R.O.I.

U.K.U.K.

Microwaveable Hand Held Sandwiches & Snacks

Microwaveable Hand Held Sandwiches & Snacks

Irish Food Processors LtdIrish Food Processors Ltd

Europe’s Largest Beef Processor

Fresh & Frozen Red Meat Processor, Manufacturer & Retail Case Ready Packer

Supplying Retailers, Foodservice & Manufacturers

Continual Investment Programme

Largest EU Import Quota (GATT licence)

Europe’s Largest Beef Processor

Fresh & Frozen Red Meat Processor, Manufacturer & Retail Case Ready Packer

Supplying Retailers, Foodservice & Manufacturers

Continual Investment Programme

Largest EU Import Quota (GATT licence)

Group turnover in excess €1bn

Employing over 3500 colleagues at more than 30 plants throughout the British Isles

14,000 cattle per week

40,000 sheep per week

Largest EU GATT quota

Group turnover in excess €1bn

Employing over 3500 colleagues at more than 30 plants throughout the British Isles

14,000 cattle per week

40,000 sheep per week

Largest EU GATT quota

Irish Food Processors LtdIrish Food Processors Ltd

IFP Markets & Customers

Canada Canada Canada Canada

ChinaChina ChinaChina

United KingdomUnited Kingdom

RussiaRussiaRussiaRussia

JapanJapan JapanJapan

AfricaAfricaAfricaAfricaMexicoMexicoMexicoMexico

IrelandIreland

ScandinaviaScandinavia

AustraliaAustraliaAustraliaAustralia

IndonesiaIndonesia IndonesiaIndonesia

GermanyGermanyGermanyGermany

New New

ZealandZealand New New

ZealandZealand

Current TradeCurrent TradeCurrent TradeCurrent Trade Previous TradePrevious TradePrevious TradePrevious Trade Current SourcesCurrent SourcesCurrent SourcesCurrent Sources Previous SourcesPrevious SourcesPrevious SourcesPrevious Sources

VenezuelaVenezuelaVenezuelaVenezuela

ABP – UK’s Leading Meat ProcessorABP – UK’s Leading Meat Processor

Turnover in excess of £550m

Employing over 2,200 colleagues at 15 plants

Processing in excess 350,000 cattle per year

Average production of 2500 tonnes of primal meat and 2000 tonnes of retail ready meat per week

Setting industry standards in every aspect of food processing

Supplying the finest fresh & frozen meat to the UK’s leading retailers, manufacturers and caterers

Turnover in excess of £550m

Employing over 2,200 colleagues at 15 plants

Processing in excess 350,000 cattle per year

Average production of 2500 tonnes of primal meat and 2000 tonnes of retail ready meat per week

Setting industry standards in every aspect of food processing

Supplying the finest fresh & frozen meat to the UK’s leading retailers, manufacturers and caterers

IFP – Plant LocationsIFP – Plant Locations

Processing at:Perth EllesmereDoncasterShrewsburyJerseyLowestoftYork NewryLurganUlsterLiverpoolBlackburnGlasgowBallybay

Processing at:Perth EllesmereDoncasterShrewsburyJerseyLowestoftYork NewryLurganUlsterLiverpoolBlackburnGlasgowBallybay

Slaughtering at:

NewryLurganPerthYorkEllesmereShrewsburyBlackburn

Slaughtering at:

NewryLurganPerthYorkEllesmereShrewsburyBlackburn

System Background

• ABP grown by acquisition and organic growth– No commonality of systems– No consistency of approach – Different business languages

• Company strategy of local responsibility• Some industry specific requirements

– Traceability– Yield analysis– ‘catch weight’

• Realisation of benefits of shared services• Led to the Movex ‘programme’

– Standardisation at an ERP level– Standardisation of systems across group– common processes wherever possible

Original Processing Systems

Abattoirs Boning Halls Further Processing

Movex

System Integration

abattoir

payment system

HCS ‘Black Box’

Scanvaegt – 2 flavours

Hellenic

HCS

Scanvaegt - 3 flavours

Hellenic

HCS

System Integration

Customer Orders Despatches CSV flat files

System Vision

Abattoirs Boning Halls Further Processing

Supply Chain Planning

ManufacturingOrders

PurchaseOrders

CustomerOrders

Stock

IntegratedFinancials

Site Planning (Boning and CPM)

Common Access Reporting

KP

I DashboardMaintenance Orders

Movex

Farmers Customers

Operator Interface

Who Are Operator

• Acquired by Intentia as part of APP purchase (~2000)

• Became independent as Operator Systems in 2004• Based in Copenhagen in the Lawson Offices• 15 employees• Only supply, develop, implement and support

Operator• Have implementation Partners mainly Scandinavia

www.operatorsystems.com

Operator – Example references

MES solution•Orders (MO, CO, WO, PO,…)•Work Instructions•Job reporting•Label Printing•Integration with

•ERP •SCADA•Quality Systems•Maintenance •Movex APP

•Online document viewer•Online machine / job monitoring•T&A•Alarms

Operator – Overview

ERP

OPERATOR

SCADAMachine Control System

Other systems

Interface solution•Uses tools from MES solution•ERP integration to

•SAP •Movex•Navision, •…..

•Interfaces to•text files•Databases (OLEDB,ODBC)•RPC•XML

•Uses internal files (jobr_generic)

Operator - Connections

• Predefined types - import / export– ERP data and orders - Items, COs, MOs, Workcenters …– ERP transactions calls (API) – MHS850, MMS310, CRS620 ……– Generic – MS SQL, Oracle, ODBC, OLE, flat file– Others (batch scripts)

• Specific Connection details– Where is it– Userid, Passwords, tcp/ip ports ….

• Instances of Connections (Unique parameters)– Mapping link– Job service details– Movex company or warehouse– Job parameters– Debug detail information

Connection Example

Connection Type : flat fileConnection : IMPORT_SHREWSBURY

d:\Intentia\OPEIS\TEST\DATA\A22\IMPORTInstances : IMPORT_SHREWSBURY

use job for all flat file importingcreate ‘end of load’ & ‘end of order’ transaction flag

Connection Type : ERPConnection : MVX_ABP

Movex user id and passwordInstances : EXPORT_JOBR

use job for all flat file importingMovex companyMapping table to use

Movex

Site export file(CSV)

Operator

Operator - Mapping

• As data is moved about where does it go to?• Supports multiple files (header to lines)• Functions

– Predefined– Specific (e.g. Secondary Unit of Measure)

Operator - Translations

• Supported different local to common central ‘language’ • Two types

– Translations (e.g. item numbers)– Cross references (e.g. Supplier codes)

• Can be made mandatory• Plant specific or global• Can be directional• Example:

– Global translation of 406123– Site specific of CBP1234 Movex

ASBFB65BR2C

ShrewsburyCBP1234

Perth406123

Newry406123

Operator – Movex API

• By Batch (controlled in the job)• Sequencing• Error control• Mapping to API call

http://www.lawson.com/reposit12/reposit.html

Operator – API Mapping

Operator - Jobs

• Variable delay time for each job• Colour coded status reporting and detail by job• Jobs run in a Service• Emailing of error conditions

Operator Jobs

Current Position

• 6 sites with basic CO and CO despatch CSV interface• 3 sites integrated COs, POs and suppliers• 1 site with full stock integration• All farmers entered into SI and updated in Movex• All farmers paid via Operator into Movex• Crates system• Item creation system

• Per week approx – 65,000 API calls– 4,500 COs (~10 lines per CO)– 300 POs (~4 lines per PO)

Flexibility - stock load

• Use CSV report of ‘stock’• Created import job • Created export job calling MMS310• Created Crystal CSV report of ‘non updated’ locations• Run them through same job

• Used as a ‘one off’ for a project start-up• Will be used for all non-integrated sites

• No (or very little) cost• Less than a days time used

Flexibility - Suppliers

• Have 18,000 farmers in System Integration payment system

• Modified SI system to have a flag in MS SQL database• Used as trigger for Import job

– set to ‘0’ by SI– ‘0’s picked up by Operator then set to 1

• Created export job to call CRS620, CRS624 and CRS622

• Small cost at SI ( < £500)• Less than 1 day

Where are we going

• Multiple servers– Spread load– Failover– Business Continuity

• Continue rollout of full stock integration• New version

– MS SQL 2005 (database performance)– Faster– Better user interface

Questions

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