Optimisation of empty packaging supply system at Van Loon Vlees

Supply of boxes lagged behind

Each line is supplied with cartons via an automated feeding system, so that production workers always have enough empty boxes to prepare the packaged products for transport.

Van Loon noticed that the supply system could no longer meet with the ever-increasing sales. To solve this problem up to three employees were stacking and transporting boxes on very busy days to provide the colleagues at the packing positions with sufficient boxes. Together with the supplier of the logistics system, they started looking for a partner to carry out an analysis of possible improvements to this system. QING eventually emerged as the appropriate party to conduct this analysis. 

Approach

After the project's kick-off, we first recreated the production environment in the virtual world using 3D simulation software. We collected data; among other things, we measured how quickly the operators could get hold of a new box. We used information such as line speed, the conditions used by the software and data from sensors in the line. Together, the data provided a clear and accurate picture of what the current status of the system was.

‍

Validation and testing

Then we ran production in the virtual world for a number of days in order to validate the model. Afterwards, various scenarios were tested with which the process of delivering the empty boxes could possibly be improved. By testing a number of scenarios, bottlenecks become visible and you can efficiently look for the best route to improve the logistics system. In this case, a mechanical adjustment and an adjustment in the control of the system, which determines under what conditions a box is sent to a certain position. Because the new situation is fully data-driven and has been tested for feasibility, Van Loon can confidently make the proposed investments.