Increase in Productivity in the Sector - Feed Factory, Responsible for the Production That Feeds Cattle

 

Increase in Productivity in the Sector - Feed Factory, Responsible for the Production That Feeds Cattle - Success Case L2 Agronegócios

GETTING TO KNOW THE COMPANY

L2 Agronegócios emerged in August 2012, from a dreamy boy who has his father as a mirror. A dream that came true becoming a family business and also for all people, a company that brings food to the tables and employs many Brazilians.

Company focused on the production of garlic, cattle and cereals, in Tiros/MG. Leonardo Rodrigues Lopes, the famous Leo Boiadeiro, known for his great ability to move animals for slaughter, through his vast breeding of animals in confinement.

CHALLENGE

L2 agribusiness stands out in the market through its products with high quality requirements, in addition to adopting the philosophy of operational excellence, strong relationships, fast and effective customer service.

In a scenario where the market is increasingly fierce, the need arose to improve its production process, aiming to reduce operating costs and implementation of production control. In this way, in partnership with Avilla Consulting, a project was started, aiming to identify opportunities for improvement in the Livestock sector, in particular we will address the Feed Factory.

In the initial mapping carried out by Avilla Consulting, some opportunities for financial gains were identified, but this case study aims to cite one in particular: At Fábrica de Ração, responsible for producing the supplements called “Pre-Mixtures”, which are later mixed with other bulk ingredients for cattle feed. The Pre-Mixes are differentiated into: Pre-Mix Recreates, Pre-Mix Adaptation and Pre-Mix Termination.

In order to increase utilization and productivity, the SIT (Integrated Technology System) was implemented in order to assess daily the reasons for not meeting the expected utilization and productivity.

The following steps were carried out:

• Implementation of SOP “Standard Operating Procedure”
• Training and identification of stops;
• Weekly Schedule;
• Implementation of the SIT “Integrated Technology System” as a way of monitoring production;
• Input Stock Control
• Weekly Pareto Analysis of Production Stoppages through SIT

L2 Agronegócios implemented production management methods and a software for monitoring indicators based on the Lean manufacturing philosophy focused on enhancing processes. Monitoring production at the feed factory was the first objective to be set for this project.

SOLUTION

The analysis model implemented by Avilla Consulting, with the objective of increasing the utilization rate and productivity of the feed mill, was based on statistical metrics and the use of the chronoanalysis method, so that an effective solution could be reached.

At first, in order to verify the capacity of the employees involved, their reasonable expectation was defined, which consists of measuring the time needed to execute one unit per hour, without any interruptions. To this end, the times for production of each type of pre-mix were measured, in addition to the launch of any stops that the factory presented during the day.

PROJECT START – Data referring to 1 week.

*Some information was withheld due to confidentiality of information

Based on the above result, it was identified that the factory had an unsatisfactory rate of use and productivity, as they frequently broke down, resulting in a loss of work rhythm and idleness of the employees who were there, in addition to the loss of productivity due to maintenance.

Usage Calculation: Hours Worked / Hours Available

Productivity Calculation: Hours Produced / Hours Available

After this finding, the stops that generate more idle time were evaluated and action plans were drawn up with priority dates for solving these problems.

Data for 1 month:

*Some information was withheld due to confidentiality of information

The 5W1H concept was used to monitor the activities, according to the layout below:

*All rights reserved to Avilla Consulting

In addition to monitoring the activities, a live schedule was drawn up, that is, the schedule is updated weekly, as the feed mill varies according to the number of oxen, weekly consumption, amount of storage.

A Dashboard was developed that is fed by data extracted from the SIT (Integrated Technology System) to identify the amount of Premixes that are used per day, week, month and year.

*Some information was withheld due to confidentiality of information

Subsequently, new analyzes showed an increase in the utilization rate and productivity of the feed mill, thus generating greater productivity in the entire process.

CURRENT DAYS - Data referring to 1 week

*Some information was withheld due to confidentiality of information

RESULTS

L2 Agronegócios achieved, with the optimization of the process, a financial reduction resulting from not missing the specific diet for cattle, an increase of 34% (percentage points) in use and 31% (percentage points) of productivity in the feed factory.

In addition to the quantitative results, qualitative gains were observed through the qualification of those responsible and managers of the process, obtaining more integration and communication between the sectors and greater engagement on the part of the teams to identify potential improvements.

This improvement, as well as all the others implemented with the Avilla project, will be perpetuated by the professional who was trained and qualified to monitor and identify anomalies in the process. Managers meet daily to discuss the indicators, as a way of engaging those involved in achieving goals and finding solutions to problems.