6 Steps for Improving Asset Utilization in Food Processing

Photo by Crystal Kwok on Unsplash

In the food processing industry, using assets effectively and efficiently is an essential prerequisite for food manufacturers to stay competitive. Optimizing asset use in the food processing industry leads to increased productivity, reduced costs and waste (which also diminishes environmental impact), and an overall boost in business performance. Listed below are six steps to improve asset usage in the food processing.

The first step in improving asset utilization is a comprehensive inventory of all assets. An asset inventory can be used to collect data on the age, usage, maintenance history, location, spare parts, and other relevant asset and equipment information. Some of this information can help manufacturers estimate the mean time between failure (MTBF), a metric that measures the reliability of machines and components and helps plan maintenance accordingly. Food manufacturers can also use asset inventories to:

Asset utilization is another important metric. It measures the effectiveness of assets in generating revenue and is calculated by dividing the actual production output of an asset by its maximum potential output. This metric allows food plant managers to identify areas for improving asset performance and optimizing food processing.

Some other metrics for measuring asset utilization include:

Food manufacturers can use IoT sensors to collect real-time data, such as pressure, temperature, electrical currents and vibrations, on the performance of food processing equipment. By analyzing this data, food plant managers can remotely monitor their assets and identify potential issues before they cause downtime or equipment failure. They can also receive an alert if a failure occurs. IoT sensors provide sufficient data to let food processing workers make quick and informed decisions that prevent or minimize downtime.

Additionally, IoT sensors are compatible with enterprise asset management (EAM) software, which provides visibility into asset performance analytics by collecting and analyzing data from multiple sources. EAM software allows food manufacturers to track key performance indicators (KPIs), such as asset uptime, maintenance costs and production yield. This way, they can identify trends and make data-driven decisions to optimize their asset utilization.

Asset tracking can help food manufacturers track asset location and condition. If the assets are equipped with a GPS tracking system, a barcode scanner or a radio-frequency identification (RFID), manufacturers can add asset tracking software to the equation and gain visibility into their assets.

Asset tracking software enables food manufacturers to:

Asset tracking software systems can be installed locally on the food plant's computers and servers, or they can be cloud-based. Most modern asset tracking software systems are cloud-based. The cloud provides food manufacturers with a centralized location to store and access asset data from any device with an internet connection. This allows them to monitor the location and status of their assets in real time, even if they’re not physically in the food plant.

Proper maintenance is essential to ensure that assets are operating at peak efficiency. Maintenance also helps extend equipment lifecycles, avoid unplanned downtime, and preserve food safety and regulatory compliance.

Apart from regular upkeep, food manufacturers can resort to predictive maintenance. This is an advanced approach to maintenance that uses technology to identify potential equipment failures before they occur. Manufacturers around the world are taking advantage of it. In fact, the predictive maintenance market is expected to be worth about $15.9 billion by 2026.

Predictive maintenance help manufacturers prevent downtime, reduce maintenance costs, and optimize asset utilization and performance via several technology solutions:

Workflow optimization involves analyzing and streamlining processes to improve efficiency and reduce costs. One way to achieve this is automating processes to reduce manual labor and improve asset utilization—e.g.,using robotics.

In the food processing industry, robots can take over repetitive tasks that humans can't always do with the same level of accuracy and efficiency, such as cutting, sorting, and packing. They can reduce the risk of errors and waste and improve product quality without the need for rework. And since they don't need to rest, they improve asset utilization by simply utilizing assets for longer periods of time. Additionally, robots can be equipped with sensors that collect asset performance data and take part in predictive maintenance, increasing uptime even more.

Data analytics and digital technologies can provide valuable insights into asset performance and help identify areas for improvement, enabling food manufacturers to plan the best asset utilization. With these steps and strategies, food manufacturers can optimize their production processes and reduce costs while increasing productivity and competitiveness.

Eric Whitley has been a leader in the manufacturing space for over 30 years. After an extensive career as a reliability and business improvement consultant, Eric joined L2L, where he currently serves as the director of smart manufacturing.