CASE STUDY

Planning and scheduling integration framework of epic proportions

Nukon

The Nukon Team : Jul 19, 2022

2 min read

Nukon developed a system to support the processing plant on a 'pull model', where raw materials are managed for maximum efficiency, driven by actual store order demand. Systems users include 8 in plant and 8 within the corporate office.

Region

Melbourne, Victoria, Australia

Client Testimonial

"The Nukon team were handed a challenge task and authority over defining the planning and scheduling system requirements. They rose to the occasion, drawing on their knowledge and experience, to deliver a great working solution with all the functionality I had committed to the board. I am very grateful." -- Chief Digital Officer

Challenge

When a major supermarket chain developed a $150 Million central product processing facility to supply their chain almost 2,500 stores nationally, they appointed Nukon to develop a planning and scheduling framework to support them.

The processing facility is of truly epic proportions, converting some 12 tonnes of raw ingredient every hour into 120 SKU's types to meet orders within 3 days. Due to the highly perishable nature of the product, a robust system was required to ensure orders from stores around the country were met, with minimum raw product wastage and the longest possible shelf life.

Outcome

With such large volumes of high value, perishable product, this client required a system that is both highly accurate and extremely reliable.

Nukon developed a system to support the complex requirements delivering outcomes including:

Forecasting

A solution for forecasting of raw material requirements, combined with the new model in distribution methodology, placing consumer packs directly onto store ready pallets that are transited directly through the distribution centre to store.

Scheduling

Store ready pallets are required to meet half hourly delivery windows where they are combined with pallets of other goods to be delivered directly to stores, to agreed and planned, transportation schedules.
Production of the freshest and highest quality product is achieved by integrating the planning and scheduling framework with the shortage and retrieval system, ensuring working stock is run out at timely intervals and cleaning regimes are undertaken as required.

Traceability

To meet consumer demands, traceability systems were developed and implemented in conjunction with the clients IT team and the processing equipment suppliers. This focused on the use of GS1 standards for ASN's (Advanced Shipping Notices) and SSCC (Serial Shipping Container Code) labelling systems, ensuring all raw materials are scanned into the processing plant, tracked through the packing process and scanned at various stages of delivery to the store. This function has the additional benefit of monitoring and improving each supplier's performance and traceability capability.

Some of the benefits delivered

Optimisation of supply chain increased shelf life for customers by average of 1.5 days
No storage requirements with product shipped directly to stores, saving $50 per pallet
Achievement of DIFOT goal of 98.5%
Full product traceability from farm to consumer.

Automated workflow solutions

Nukon delivers powerful workflow solutions that can orchestrate machines, systems, and people in a production environment. Workflow solutions can enforce adherence to production processes, prescribe tasks to the right users at the right time, reduce time spent monitoring assets and allow operators to focus on continuous improvement activities.

Custom solution

Nukon’s solutions are fully customisable, because no one client is the same. Starting from a basic model and a workflow template, you’ll be able to add your own data in a structure that suits you, and create or enhance workflows to suit your individual processes.

Real-time data and tools transform quality system and empowers team