Food & Beverage ERP

Food Safety and Compliance

Comply with food safety requirements with traceability, quality and preventative functionality. Account for all of their raw materials and finished goods throughout the production process and be fully recall ready.

• Bi-directional ingredient and product traceability and recall
• Quality hold management
• Allergen management
• Quality checks and audits
• Preventative maintenance
• Pre-receipt inventory entry compliance

Traceability & Lot Control

• Aptean’s Food & Beverage ERP’s lot algorithm can be set up on the item card; finished goods, intermediate items, and even raw materials can be assigned a lot algorithm that is then transferred to an item’s label for barcode scanning
• External lot numbers can also be tracked, in the case of vendors assigning lot numbers
• Lots are consumed in order of expiry, picking controls are in place to prevent products being consumed out of rotation unless otherwise approved by the supervisor
• Bi-directional traceability is available at the click of a button; any item/lot combination can be traced providing information related to purchase, consumption, output, shipping as well as any other items that may have been cross-contaminated

Recall Process

• Bi-directional lot trace can be extended to the recall process
• Recalls provide a list of all customers impacted by a concerned item and lot combination
• Recall data can be exported to Excel for manual manipulation
• For recalls, an auto-generated Word template letter that can be emailed or faxed to customers
• Recall letter can communicate impacted lots, and provide information related to the shipment number, date, quantity shipped prompting response from customers for next actions.

Quality Management

• Setup unlimited quality procedures related to items, customers, assets, employees, or other entities in the business
• Quality procedures can mandate certain steps that need to be carried out, providing work instructions to employees
• Expected results can be defined, if during a quality audit, results are outside of range, certain actions like product quarantine can be initiated
• Quality audits can be initiated at certain material movements like receiving, pick, consumption, output, or shipping
• Quality audits can be captured electronically and in real-time using RF barcode scanners, tablets, or computer carts
• A quality specific role center provides a view of quality audits in a matrix format to make it easy to see what quality audits are due to be performed

QR Codes

Aptean Food & Beverage ERP has some clever applications for QR codes – matrix barcodes that can be read by mobile devices and other readers – specifically around food safety. Customers, and even consumers, can scan an item’s QR code to access a website that directly links to Aptean Food & Beverage ERP’s database. Consumers or customers can find out additional information about that item or even the specific item lot such as nutritional information, ingredient declarations, allergen declarations. Additional information related to production facility, supervisor or staff, and quality audit results can be presented as well. Integration to Facebook and Twittere can be included allowing for easy product feedback,​‘likes’, or re-ordering.

Plant

• Plant provides an alternative to recording output and consumption in real-time
• Optimized for either a wash-down touch screen computer located on the floor, or alternatively tablet computer
• Presence close to the floor makes it easier for timely data capture
• Touchscreen interface is simplified for employees not familiar with computers
• Functions include recording of output and/or consumption
• Real-time views of important KPIs like expected-to-actual output, and other metrics
• Visualize production schedule for a given machine center or even shift

Manufacturing / Production Module

Manage production scheduling and planning through to batch processing and consolidation. Integrated production data breaks down barriers between departments and allows for more efficient production and distribution.

• Master production schedule (MPS) planning
• Batch / item production consolidation (grouping similar items into same production window)
• Capacity and bottleneck management
• Define and execute equipment operation steps
• BOM
• Reverse BOM
• Net BOM requirements and calculations
• Multi-plant production management
• Co-packer management
• Co-product management
• Production cost analysis
• Yield reporting
• Allergen management
• Production forecasting
• Activity based costing (labor)
• Add-on: advanced reporting and analytics
• Add-on: JustFood Plant: recording of manufacturing execution

Preventative Maintenance

• Integrate full maintenance planning and corrective action into Aptean Food & Beverage ERP
• Work orders, MRO purchasing, fixed asset management, and production scheduling is fully integrated with the PM module
• Track and record calibration results, analyze fault reasons and fault effects
• Fully track cost of maintenance per unit of measure (cycle, hour, etc.)
• Group work orders by group allowing for instant trendscape analysis by day, month, quarter, or year

Production Execution

• Record production in a variety of ways; using either flushing methods or the more accurate method of actuals recording; production can be entered in sequence of consumption and output, or out of sequence depending on a customer’s requirements
• Consumption and output can be recorded manually from paper off the floor (preserve existing processes with limited impact to employees)
• More timely options including barcode scanning and touch screen recording 
• Integration to machine execution systems (MES) or PLCs for ingredient consumption
• For variable weight scenarios, integration to scales
• Instructions for machine centers or workstations can be printed or displayed using touch screens

Production Metrics

• Visualize key performance metrics in real-time or via exception reporting
• Our production KPI module is optimized for Windows Surface tablet or large screen monitor running Windows
• Production metrics that are visualized can be tailored for each specific customer to communicate metrics that are important to the company
• Production statistics by shift or by production order including expected to actual output, expected to actual costs, yield, capacity, labor efficiencies, and more

Production Scheduling

• Graphical production scheduler makes scheduling your production lines easy using an intuitive, color-coded drag and drop interface
• Production schedules can be defined by priority sequence to minimize sanitation, change over and production downtime; for example, light to dark, allergens last, etc
• Production schedules and capacity overviews can be viewed in a grid format or visually
• Incorporating the concept of routing, each recipe can identify production steps
• Each step is related to machines or work centers which are defined by capacities
• Capacities help determine production schedules and potential conflicts

Quality

Set up mandatory quality audits and checks from pre-receipt of materials all the way to output and shipment. Customize quality audits and checks so that they meet the unique needs of your production process.

• Support SQF/ BRC/ FSMA / GFSI / HACCP initiatives
• Quality audits and checks (pre-receipt-to-entry-to-exit)
• Pre-receipt inventory entry compliance
• In-process quality checks and audits
• Control release and delivery of goods (based on audit)
• Date-based audits (GMP, food safety, premises, etc.)

R&D and Product & Development

Use production and recipe management data to experiment with new formulas and ingredient amounts. R&D teams are able to compare current recipes and processes with new combinations to unlock new products, recipes or cost effective formulas.

• BOM costing
• Custom item attributes (new)
• Nutritional information calculation
• Ingredient declarations
• Lab and production formula management
• Formula version costing and comparison
• Customize workflow to manage item product introduction and approval (new)