Food and beverage industry is categorized by issues such as regulatory compliance (FDA 21 CFR 11), quality standards, consistency, raw-material price escalations, increasing variety etc. The working environment is becoming competitive day by day with new entrants entering and taking up market share. All these factors necessitate the need for streamlining the operations and achieving operational excellence. Sensys provides state of the art solutions to address these issues such that food & beverage companies can feel secure about their operations and standards. Our open, scalable, simplified architecture lays strong foundation to help companies achieve flexibility as well as operational excellence. We provide complete solutions ranging from procurement of raw-materials to manufacturing and packaging of food and beverages.
Our aim is to provide complete visibility and traceability throughout the supply chain thus ensuring overall operational excellence and enterprise wide visibility.
Sensys ground breaking technology addresses the needs of Food & Beverage Customers through its industry specific solutions tailor-made for Food & Beverage industry. Our solution portfolio includes:
Operator Level/ Centralized HMI
Sensys provides state of the art customized high resolution representation of plant floor and processes to ensure visibility and traceability of the entire operations in a plant and enabling the management to perform monitoring and control on real-time basis. We offer operator level console as well as act as a centralized platform in case of multiple facilities thus catering to entire needs of the company.
Information Management System
Sensys offers a state of the art information management system with advanced historian capabilities that allows data collection, data storage, data archiving and instant data retrieval upon user request. This enables clients to centralize data from various data sources and provides a central platform to access historical data. This data can further be used to perform in-depth analysis on processes and operations, advanced reporting (periodic and customized) and various trending techniques for better understanding and decision making.
Overall Equipment Effectiveness
SENSYS’s state of the art IntelliMAX EMI solution provides a comprehensive way to monitor and improve the overall efficiency of production processes through its OEE module. IntelliMAX EMI tracks key metrics contributing to OEE i.e. availability, performance and quality and provides users contextual analysis at equipment, assembly, facility and plant level. IntelliMAX EMI’s OEE dashboard enables users to analyze Planned vs Actual OEE, Visibility of key reasons causing downtime, Knowledge of reasons attributing to performance loss and causes contributing to poor quality. This results in better utilization of the assets and production lines which improves productivity and profitability.
Energy consumption is getting critical all the time for any manufacturing organization. Sensys provides Food & Beverage specific Energy dashboards in order to enable users to take necessary measures to optimize energy. IntellIMAX EMI provides visibility to system by providing real-time monitoring and control of energy parameters for both supply and demand (consumption). By having an accurate data about energy consumption, user can better estimate patterns and perform in-depth analysis to optimize the supply and demand for energy. We offer load balancing and optimization taking into account the demand in real-time. This results in secure and reliable energy availability, improved energy efficiency and better profitability.
Planning and Execution
IntelliMAX EMI comes with a fully blown Planning and Execution System which ensures that Manufacturing Orders originated from the Planning department are executed as per schedule. The actual execution is tracked and users can perform analysis later on Planned vs. Actual execution of operations to meet production targets. Any glitch or event that affects the delivery is historized and can be completely tracked and analyzed to determine the root cause failure in order to make sure that such an event does not occur in future.
FDA 21 CFR Part 11
IntelliMAX EMI supports complete compliance with the FDA 21 CFR 11 regulatory standard used in Food & Beverage and Pharmaceutical industries. IntelliMAX EMI tracks each and every change that occurs in the system be it System Events, Process Events, Operator set points, or user log ins. All of this helps to provide authentic audit trails. IntelliMAX EMI keeps a proper record of FDA regulated information and tracks approval of each activity through electronic signatures. Advanced visualization and analysis is available on all events that occur. Comments and reasons against each event are properly logged and displayed. IntelliMAX EMI also support comprehensive reporting of all events in various formats (excel, PDF, html).
Recipe & Batch Management
Sensys comes up with a highly efficient, customizable Recipe Management system for food and beverage companies which enable them to develop/formulate recipes as per requirements, act as a standardized database for storage of recipes, logically categorize recipes and also integrate with other business applications like ERP etc. In addition, it enables users to adjust recipes as per actual scenarios and also provides traceability for all batches, products and their ingredients. IntelliMAX EMI also completely supports the ISA-88 batch management standard.
Integration with ERP
The power of real-time data is fully harnessed when it is utilized not only at plant floor but also with other manufacturing and business applications. IntelliMAX EMI has the capability to integrate the plant floor data with other manufacturing and business applications such as SAP, Maximo etc. This facilitates information sharing across various business functions thus improving coordination and ensuring faster decision making. In Food & Beverage, it is vital to integrate real time information of batch execution with ERP systems. In addition, condition based maintenance of assets are a key requirement for the Food industry. IntelliMAX EMI (being SAP and Maximo certified) completely addresses the needs of Plant Floor – ERP integration.