AVI Volendam keeps up with the times
Our team always critically examines where improvements can be made. We continuously make improvements in the area of sustainability, for example by reducing plastic use and recycling as much as possible. Recently, our ERP system also received an upgrade.
Complex Production Process
We deliver approximately 1500 end products. Some of these are one-time, while for others, customers place repeat orders. The base material for each package is the same. This is transformed into a custom end product by about 40 AVI employees across three different departments. First, the plastic granulate is processed into a film product. That film product can then be printed, and finally, the product is finished (sealed, cut, rolled, etc.). You can imagine that the one-time nature and the unpredictability of repeat orders can make the planning process quite challenging, especially since we always want to deliver fast service. Yet, we planned production for 25 years using Excel and plastic trays. That could be improved!
Automation with Exact
We have now switched to Exact for Production in combination with the Smart Production Suite from partner Smart Production Solutions. A logical step, as we were previously satisfied with Exact for DOS and Exact Online. We use Exact for Production for sales, work preparation, and accounting. The shop floor is now managed via Smart Production Solutions. The work orders are presented on tablet computers, and the processing times are also recorded on them. As a result, we are well on our way to a paperless shop floor.
Getting Used To It
It's always exciting to see how the transition to a new system goes. The biggest challenge was the mass balance. Previously, it was recorded on paper how many kilograms of plastic granulate were used and how many kilograms of product were reported ready. The differences could be explained by different types of cutting losses. It was a puzzle to get this right in Exact Online, but now this is completely in order.
Growth Opportunities
The biggest advantage of automation is that in the future, we will be even better able to continue improving. The next improvement step is the registration of machine malfunctions and the registration of quality characteristics such as film thicknesses and waste in Exact. The standards of BRC Packaging (global standard for packaging materials) and ISO 9001:2015 are regularly updated and adjusted. As a result of the introduction of version 6 of BRC, we have also implemented the "release of the production line" in SPS. This ensures that food safety always receives the attention it deserves.
In short: we are (and remain) completely up-to-date!