Unlock the full potential of your food processing operations with these six steps to improve asset utilization.
Efficient use of assets is critical for food manufacturers in the food processing industry to maintain their competitiveness. Optimizing the use of assets not only improves productivity but also reduces costs and waste, which ultimately has a positive impact on the environment. This, in turn, leads to an overall improvement in business performance. Below are six steps that can be taken to enhance the usage of assets in the food processing industry.
1) Conduct an Asset Inventory
The first step in improving asset utilization is a comprehensive inventory of all assets. An asset inventory can be used to collect data on the age, usage, maintenance history, location, spare parts, and other relevant asset and equipment information. Some of this information can help manufacturers estimate the mean time between failure (MTBF), a metric that measures the reliability of machines and components and helps plan maintenance accordingly. Food manufacturers can also use asset inventories to:
2) Measure Asset Utilization
Asset utilization is another important metric. It measures the effectiveness of assets in generating revenue and is calculated by dividing an asset's actual production output by its maximum potential output. This metric allows food plant managers to identify areas for improving asset performance and optimizing food processing.
Some other metrics for measuring asset utilization include:
3) Monitor Equipment Performance
Food manufacturers can use IoT sensors to collect real-time data, such as Steam pressure, temperature, electrical currents and vibrations, on the performance of food processing equipment. By analyzing this data, the engineering team can remotely monitor their assets and identify potential issues before they cause downtime or equipment failure. They can also receive an alert if a failure occurs. IoT sensors provide sufficient data to let food processing workers make quick and informed decisions that prevent or minimize downtime.
4) Implement Asset Tracking Software
Asset tracking can help food manufacturers monitor asset location and condition. If the assets are equipped with a GPS tracking system, a barcode scanner, or radio-frequency identification (RFID), manufacturers can add asset tracking software to the equation and gain visibility into their assets.
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Asset tracking software enables food manufacturers to:
Asset tracking software systems can be installed locally on the food plant’s computers and servers or cloud-based. Most modern asset-tracking software systems are cloud-based. The cloud provides food manufacturers with a centralized location to store and access asset data from any device with an internet connection. This allows them to monitor the location and status of their assets in real-time, even if they’re not physically in the food plant.
5) Develop a Maintenance Plan
Proper maintenance is essential to ensure that assets are operating at peak efficiency. Maintenance also helps extend equipment lifecycles, avoid unplanned downtime, and preserve food safety and regulatory compliance.
Apart from regular upkeep, food manufacturers can resort to predictive maintenance. This is an advanced approach to maintenance that uses technology to identify potential equipment failures before they occur. Manufacturers around the world are taking advantage of it. In fact, the predictive maintenance market is expected to be worth about $15.9 billion by 2026.
Predictive maintenance helps manufacturers prevent downtime, reduce maintenance costs, and optimize asset utilization and performance via several technology solutions:
6) Optimize Workflow
Workflow optimization involves analyzing and streamlining processes to improve efficiency and reduce costs. One way to achieve this is by automating processes to reduce manual labor and improve asset utilization—e.g., using robotics.
In the food processing industry, robots can take over repetitive tasks that humans can’t always do with the same level of accuracy and efficiency, such as cutting, sorting, and packing. They can reduce the risk of errors and waste and improve product quality without the need for rework. And since they don’t need to rest, they improve asset utilization by simply utilizing assets for longer periods of time. Additionally, robots can be equipped with sensors that collect asset performance data and take part in predictive maintenance, increasing uptime even more.
Data analytics and digital technologies can provide valuable insights into asset performance and help identify areas for improvement, enabling food manufacturers to plan the best asset utilization. With these steps and strategies, food manufacturers can optimize their production processes and reduce costs while increasing productivity and competitiveness.