Modeling,analysis and continuous improvement of food production systems: A case study at a meat shaving and packaging line

In this paper, we introduce a case study at a meat production company to analyze and improve the throughput of a meat shaving and packaging line. An analytical model has been developed and validated by the data collected on the factory floor. The method is based on an iteration procedure using aggregations. It is shown that the model provides an accurate estimation of line throughput comparing with actual production, with difference around 2%. Then, a bottleneck indicator based on probabilities of blockage and starvation has been used to identify and mitigate the bottleneck machine, which is referred to as the machine that impedes system performance in the strongest manner. The MVAC bubble sealer station is the bottleneck of the system, and reduction of its downtime, in particular, the downtime related to film and zipper changes, can lead to a significant improvement of line throughput. Recommendations are provided to the plant management to implement the changes.