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Anglo Beef Processors Ltd

Anglo Beef Processors Ltd. Case Study Operator. November 2006 davebarratt@abpltd.com. R.O.I. Who are ABP?. Fresh Beef & Lamb Processor & Retail Packing . Dedicated Frozen Burger Production . Fresh Beef & Lamb Processor & Retail Packing . Frozen Meat / Products & Burgers

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Anglo Beef Processors Ltd

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  1. Anglo Beef Processors Ltd Case StudyOperator November 2006 davebarratt@abpltd.com

  2. R.O.I. Who are ABP? Fresh Beef & Lamb Processor & Retail Packing Dedicated Frozen Burger Production Fresh Beef & Lamb Processor & Retail Packing Frozen Meat / Products & Burgers Largest Own Label Burger Producer U.K. Freshlink Foods Microwaveable Hand Held Sandwiches & Snacks

  3. Irish 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)

  4. Irish Food Processors Ltd • 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

  5. IFP Markets & Customers Scandinavia United Kingdom Ireland Russia Germany Canada Japan China Venezuela Mexico New Zealand Africa Indonesia Australia Current Trade Previous Trade Current Sources Previous Sources

  6. ABP – 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

  7. IFP – Plant Locations Slaughtering at: Newry Lurgan Perth York Ellesmere Shrewsbury Blackburn Processing at: Perth Ellesmere Doncaster Shrewsbury Jersey Lowestoft York Newry Lurgan Ulster Liverpool Blackburn Glasgow Ballybay

  8. 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

  9. Original Processing Systems Movex CSV flat files Despatches Customer Orders Abattoirs Boning Halls Further Processing System Integration abattoir payment system HCS ‘Black Box’ Scanvaegt - 3 flavours Hellenic HCS System Integration Scanvaegt – 2 flavours Hellenic HCS

  10. Operator Interface System Vision Common Access Reporting Supply Chain Planning Site Planning (Boning and CPM) Stock Movex Purchase Orders Integrated Financials Manufacturing Orders Customer Orders KPI Dashboard Maintenance Orders Abattoirs Boning Halls Further Processing Farmers Customers

  11. 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

  12. Operator – Example references

  13. Operator – Overview ERP • 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 • 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 SCADA Machine Control System Other systems

  14. 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

  15. Connection Example Movex Connection Type : ERP Connection : MVX_ABP Movex user id and password Instances : EXPORT_JOBR use job for all flat file importing Movex company Mapping table to use Operator Connection Type : flat file Connection : IMPORT_SHREWSBURY d:\Intentia\OPEIS\TEST\DATA\A22\IMPORT Instances : IMPORT_SHREWSBURY use job for all flat file importing create ‘end of load’ & ‘end of order’ transaction flag Site export file (CSV)

  16. 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)

  17. 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 Perth 406123 Newry 406123 Shrewsbury CBP1234

  18. Operator – Movex API • By Batch (controlled in the job) • Sequencing • Error control • Mapping to API call http://www.lawson.com/reposit12/reposit.html

  19. Operator – API Mapping

  20. 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

  21. Operator Jobs

  22. 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)

  23. 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

  24. 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

  25. 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

  26. Questions ?

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