Beef processor increases spec accuracy by 30%

An industry-leading beef processor partnered with FloVision Solutions to address yield loss and quality concerns for striploin primals. With a goal to reduce product and financial loss, they installed the FloVision Pro at their plants. FloVision Pro used lasers & feedback systems to identify and correct a customer spec that was routinely overtrimmed by 12mm on average.

KEY MODULES

Laser Guidance

Specification Measurement

Specification Optimization

Staff Skills Analysis

Operator Feedback

$68,400

identified loss over 12 months

3,420 KG

yield increase over 12 months

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$68,400
identified loss over 12 months

3,420 KG
yield increase over 12 months

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Challenge

A leading beef production plant processes 300 head per day, with a variety of customer specifications for each feature and cut. On their most profitable cut, striploin primals, the backstrap refers to a piece of gristle on the length of the fat side that is removed for customer quality. Backstrap removal had a spec of 25mm (1 inch) for all customers, with the exception of one customer that required a 10mm (.4 inch) backstrap.

With their previous method, butchers measured backstraps by eye; under the perception that the 10mm spec was too small compared to the other specs, they consistently trimmed more than necessary. Supervisors very rarely screened for accuracy, and deviations from the 10mm spec were not immediately apparent. This manual approach resulted in the 10mm customer spec being overtrimmed by 12mm on average, while the 25mm backstraps were typically trimmed within 2mm of the spec.

Solution

To address this quality issue, the beef processor implemented the FloVision Pro, which features laser trimming guides for butchers, sensors that measure primal features, and a manager dashboard with data and trend analytics.

The butchers used the FloVision Pro laser guides to accurately measure and trim the backstrap customer spec for every primal. Floor supervisors confirmed that butchers utilized laser guides, eliminating the perceived need for overtrimming. Company management reviewed the data, with a specific focus on trends in the 10mm backstraps. The FloVision Pro provided real-time and daily feedback on the primals and identified clear trends that went unnoticed without systematic measurement and monitoring.

Results

The FloVision Pro recovered significant yield and profit for the beef processor. The overtrimming and failure to meet the 10mm customer spec resulted in a $0.91 yield loss per primal. With 300 primals per day being processed to this 10mm spec, correcting this error recovered $273.60 per day, and $68,400 yearly for just striploin primal backstraps for this customer.

"The FloVision Pro system brought unapologetic, honest data and feedback loops. When you have a FloVision Pro, it's obvious what is wrong and what is right. That really unlocks a lot of control and value on the boning hall floor."

OPERATIONS MANAGER