Tyson Foods Saves $60k Annually by Visualizing Smart Manufacturing Data BENEFITS TO OUR NATION US poultry, beef and chicken processors produce $296 billion worth of protein
Project Objective
Improve operational efficiencies and reduce waste by implementing sensors and software to monitor material and machines throughout the manufacturing process. The algorithms will be implemented via the CESMII Smart Manufacturing Innovation Platform (SMIP). Access to real-time production data will enable process control decisions in the context of material flows and manufacturing operations. P T6#y
Benefits to Industry
Tyson Foods is the world's second largest processor and marketer of chicken, beef, and pork. Tyson’s Texarkana, Arkansas rendering facility spends between $3-4 million per year on energy. A 2% improvement in energy efficiency gained by implementing Smart Manufacturing tools and techniques will result in an annual savings of $60,000 to $80,000 at the Texarkana facility alone. If Tyson implements Smart Manufacturing tools at all 185 of its chicken processing plants, the company could reasonably expect savings of $11 to $15 million annually on its energy bill. As Smart Manufacturing techniques are adopted industry-wide, American chicken, beef and pork processors could save hundreds of millions of dollars annually.
Technical Approach
Implement the ThinkIQ sensing and tracking platform and the CESMII Smart Manufacturing Innovation Platform to capture data from manufacturing process sensors and manual data sources. Model the equipment and associated attributes to trace material movements throughout the processing line. Identify opportunities to improve yield and measure results. Develop data visualization dashboards to display manufacturing metrics.
Accomplishments
- **The Smart Manufacturing Innovation Platform was configured to meet the needs of Tyson’s rendering facility. Key features:
- Home page highlighting performance of key process attributes
- Meat Rendering Library (profile) to simplify future expansion
- Quality dashboards display current performance, target performance, and historical average performance for key ingredients
- In-line quality devices (i.e. Near Infrared – NIR) connected directly to Smart Manufacturing Innovation Platform
- Process notifications based on user configured settings
- Program management documented and delivered within the platform
Deliverables
- Complete platform setup including installing connectors to plant data sources and validating data integrity
- Complete configuration of the SMIP and ThinkIQ system functionality
- SMIP installed, configured and tested
- Smart Manufacturing Profile for Rendering Manufacturing Operations developed and documented
- Yield reporting and analysis functionality designed, implemented, and tested
Reusable Outcomes
- Food processing equipment SM profiles
- Energy consumption models