Course
Assignment
“Material
Management” practices and Industrial Visit
Content:
Introduction:
The
present research starts with the industrial analysis with respect to Meat and
Livestock industry, processing of livestock and export of fresh chilled meat
product at respective destination.
Meat and livestock industry:
Meat
and livestock industry in the recent past has emerged as the part of
agriculture industry of Pakistan and it is contribution to the GDP is
increasing every year. Since more then 30- 35 million people are employed in
the agriculture industry across Pakistan. Livestock production and cattle
farming is one of the essential and part of rural culture across Pakistan.
In
the recent past is has been observed that Pakistan has been able to cater the
demand of mid eastern world with the fulfillment of demand of Halal Meat
products (mutton, beef ). Pakistan in comparison to other countries has
slightly upper edge when it comes to Halal Meat Market as it is representative
of Islamic countries across the globe.
The
basic material management at the slaughterhouse is what we call lean production
system that works in line with the Just In time philosophy. Basic raw material
is the meat carcass whether it is beef or mutton (cattle or goat /sheep
carcass) they are brought as per the client order. However in peak season where
suppliers are un- able to meet the demand, normally safety stock is holded in
the holding area of the slaughter house but are not kept for more then 2 -3
days .As we know that it is highly imperative for the suppliers to work closely
with integration when there is lean operation system. The basic reason for lean
production system is to eliminate chances of affecting quality (as there is
different atmosphere in rural Sindh areas compare to Karachi), Its cost
effective means no feeding cost for livestock and meeting the customer
requirement of the customer when he requires the shipment.
The process:
The
process starts with the slaughtering of livestock whether they are cow/bull
heads or sheep/goat heads according the Islamic Shariah Zabeha process which is
a manual process. The animals are left for estimated time so the blood gets
drained and carcasses are ready for de-skinning process to be started.
Methods of Waste Management:
During
the process which incur time and causes problems during the slaughtering, waste
management process is done parallel during the cleaning of carcasses, de skinning)
the waste management includes collection of blood, offal’s, organs etc.
Inventory of Livestock
Livestock
numbers are essential to evaluating the potential supply available to a meat
processing facility and to the sizing of such an operation. One can also assume the supply will expand to
some extent to meet the demand created by an effective marketing program.
Processing Time and Order Size:
Processing
time for goat/sheep heads takes 200 heads to be processed in 2 hours approx.
The container size for one shipment is 1500 kg .The average weight for 200
heads make 1 container of 1500kg. While processing time for 12 heads of
Cow/Bull to make 1 container of 1500 kg takes around 1.5 hours.
Flow of Material (Carcasses) during processing:
There
are different processes, where the carcasses under go before they are ready to
be shipped. First the slaughtering it
self, processing, de-skinning .Next it goes to the packing hall where all the
carcasses are checked for quality inspection. Carcasses are further trimmed if
they have extra wounds. Finally the Post mortem stage undergoes where the
quality checker rejects the heads which are very weak or diagnosed as not fit
for human consumption.
After
the post mortem stage the Labor starts hanging pieces in the chiller room where
they are finally prepared to be chilled.
Chilling
time for mutton carcasses takes 8-10 hrs while takes 15-17 hours for beef heads
due to their large size. The operation of cold rooms
must take into account the storage requirements of the produce, rules for
loading, maintenance and hygiene, and the running and maintenance of the
refrigeration equipment.
The loading plan will depend on the type of cold chamber, whether
it is for preliminary chilling
Preliminary chilling, which is done in the slaughterhouse itself,
depends on the slaughtering rate as this determines the amount of meat to be
chilled hourly. To avoid keeping the store door continuously open, freshly
killed warm carcasses are separated into lots and introduced into the chilling
chamber every half hour, for instance.
Carcass movement inside the store should be designed in such a way
that warm and wet meat faces the air from already chilled carcasses.
Overhead rails must be placed so carcasses are oriented in the
sense of air circulation, and to prevent them from touching each other.
It is sometimes advisable to divide the total chilling capacity
among a few chambers, computed on two hours' slaughtering, when the capacity is
high enough (10–40 t/day). Another option for high slaughtering capacity (over
40 t/day) is the continuous chilling system, where carcasses pass through a
chilling tunnel transported by a mechanical conveyor for two to four hours and
are then put in a cold chamber to undergo final chilling.
Chilling facilities should be systematically emptied after
chilling and before preparing for the following day's production.
Already chilled carcasses are placed in a refrigerated store. The
storage rooms should be at least equal in capacity to the chilling rooms.
If fresh meats are intended for quick distribution they should not
leave the chilling facilities until the temperature of the warmest point is
below 7°C, meaning an average temperature of about 2°C.
After
chilling and 3 hours before they are ready to be transferred to chiller van
.The next stage starts cloth packing , the carcasses are packed in cloth and
transferred in chiller van .Finally the vehicle starts its journey on the way
to airport.
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Storage and Material Handling:
We can categorize the
material storage and handling system has basic management functions or basic
objectives when it comes to material management.
1-
To get the best possible results in terms of
Chilling , proper chilling by the time carcasses are ready for shipment
2-
To do the process at lowest operating cost
3-
To avoid any technical problem to incur in
plant by maintaining them up to standards.
For
proper stock control certain forms must be completed in order to plan, organize
and control handling. These include loading/unloading sheets, packing and
weight lists, pallet cards for FIFO and location, room temperature and relative
humidity sheets
The
management of perishable produce, generally kept for short periods, must be planned
on the basis of a storage capacity large enough for almost all the plant's
production.
To
reduce operating costs it is of primary importance to keep accurate records and
analyse them periodically either in summary sheets or, preferably, in graphs
which show trends and any sudden variation more clearly. This makes it easy to
refer to any incident, observing the time and working conditions under which it
took place.
Manufacturing Planning and Control:
Forecasting:
Forecasts
are normally made in line to the consistent orders placed by customers and
stock purchasing is made according to even distribution of orders through out
the years for instance if 3 containers are limited order for goats/sheeps So we
must arrange 600 heads per week. However if there is any drastic change like in
the month of Ramadan and Hajj Season , advance purchases are made during these
months do fulfill the demand of customers.
Master Planning:
As
discussed above in the forecasting section that orders are normally forecasted
based on current trend of customer requirement similarly in order to set a
master plan for operational management .Within the JIT environment it is
important to have consistent order schedule so as lead times are kept short.
Weekly plan gives slaughterhouses a glimpse of how to organize different
activities for example how much labor will be required for slaughter house,
time to organize the chiller capacity and its effective utilization. So weekly
plan gives an idea how effectively material flow can be organized. During the
peak seasons planning horizon are shortened due to fluctuating pattern or
during an event where promotional activities to increase customer orders are being
performed.
Material Requirement Planning:
Basic
material are the carcasses themselves unlike to any multiple bill or assembly
its simple processing of meat carcasses. So orders are placed when to local
suppliers to arrange supply when we have appropriate customer schedule
Similarly
capacity function is adjusted according to the over all production plan during
a week. It determines the total slaughtering per day for example on full load
we have processing of up to 30-35 ton. It is obvious extra labor force will be
required , back generators are checked during load shedding , loads are
adjusted and lastly timely supply of stock for effective management
Purchasing
Issues in purchasing often arises due to
seasonal changes , this may cause
1- Poor
quality
2- Delay
in supply due to transportation routes
3- Sudden
change in prices
So
negotiations with suppliers are made in line to the above mentioned factors.
Global International
Practices:
Globally the pattern is
different for slaughtering practices are fully automated as they work on both frozen meat and chilled
meat .Since the work is on economies of
scale so fully automated chains are used to move carcass from one floor to
another making it efficient management
of slaughter house . Different forklifts are used to move the carcasses
rather then loading of carcasses manually.
Further more advanced
techniques are used of waste management in slaughter houses in austrailia (
considered to be biggest supplier of halal meat across the globe).
So the basic difference we
found in global and local slaughter houses are use of advanced fully automated
slaughter house which tend to remove the following flaws:
Production problems pertaining to the absenteeism
of work force making it highly dependent in manual slaughter houses or what we
can call them semi automated plants .
Recommendations:
Effective Waste Management: For example
animal blood is wasted locally while it is utilized in modern developed
countries making it use for different chemicals other proper factors to be
worked on are mentioned here below :
·
Supplies
of energy
·
Supplies
of machines, equipment etc.
·
Supplies
of detergents and disinfectants
·
Requirements
for buildings
·
Possibilities
for employment of trained staff
·
Organization
of slaughtering
·
Types
of animals slaughtered
For the safe disposal of liquid and
solid waste, the following action should be taken:
Separation of blood
Screening of solids
The blood from slaughtered animals will
coagulate into a solid mass, which may block up both open and closed drains. It
is therefore recommended that the blood is collected and used for human
consumption, stock feed production or fertilizers
Effluents from slaughterhouses always
contain small amounts of fat (melted fat or small pieces of fatty tissues).
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