Production process optimization (Smart Process)

With more than 10 years of experience in process optimization, increased productivity and profitability, Mecanicad has proven to be a strategic ally for various industries. A notable case is our collaboration with Turion, a company in the agricultural sector dedicated to the cultivation, processing and distribution of asparagus. Through an exhaustive analysis and the implementation of significant improvements, we managed to optimize the layout of your plant and, therefore, its operational efficiency.

Analysis of the Initial Context

Turion is responsible for managing the entire asparagus process, from cultivation to harvesting, trimming, packaging, and distribution. However, they were facing significant challenges in the layout of their plant, which was negatively impacting their productivity and operational costs.

Findings and Improvement Opportunities

Our analysis revealed that 20.71% of the cycle time did not generate value, resulting in a high daily monetary loss. The main problems included cross-flow in operations due to inadequate area distribution, inefficient manual processes, waste, inappropriate methods used that generated productivity limitations, and insufficient use of storage space.

Process Flow Optimization

We identified unnecessary paths of up to 40.6 meters and intersections that disrupted the continuous flow of people and products. Our proposal involved redesigning the flow, reducing the paths to 34 meters, and enhancing the consistency and continuity of the process. This led to significant savings in transportation and movements.

Optimizing Storage Space

The cold storage room of Turion was not being utilized efficiently, with inadequate shelving and inefficient inventory control. We proposed a vertical storage system with FIFO shelves (first in, first out), optimizing space and improving inventory control. This reorganization decreased transfer and movement times from 708 to 674 minutes.

Trimming Process

Asparagus trimming process  was a manual operation with a high level of waste. We implement good practices and provide alternatives for optimal use of trimming waste, such as animal feed, organic fertilizers and cosmetic products. Likewise, we managed to offer a solution and propose a tactic to implement the composting method, since Turion had a composting project underway with Californian worms, converting waste into valuable organic fertilizer for its crops.

Expansion of Production Capacity

Rising demand required Turion to increase its production capacity. We designed a new layout for an expanded plant, correcting and optimizing the flow and storage of the product in process. These improvements will allow Turion to respond efficiently to market demands and plan its international expansion.

Collaborating with Turion has presented Mecanicad with a rewarding opportunity. It has enabled us to apply our expertise in process optimization to a specialized product like asparagus, furthering our mission of enhancing productivity and profitability for businesses. This partnership not only enhances Turion's operational efficiency but also bolsters our capability to tackle intricate challenges across various industrial sectors.

At Mecanicad, we remain committed to continuous improvement and innovation to help our customers achieve their productivity and profitability goals.

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